Ford Transit Connect Workshop Manual l4 2 0l 2010

Factory Workshop Manual
Make
Ford
Model
Transit Connect
Engine and year
L4-2.0L (2010)
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This manual was submitted by

Anonymous
Date
1st January 2018
Ford Transit Connect Workshop Manual (L4-2.0L (2010))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Communications Control Module > Component Information > Locations > Audio Control Module (ACM)
Communications Control Module: Locations Audio Control Module (ACM)
Communications Control Module > Component Information > Locations > Audio Control Module (ACM) > Page 8
Communications Control Module: Locations In-Dash Computer Junction Box
Communications Control Module > Component Information > Locations > Audio Control Module (ACM) > Page 9
Communications Control Module: Locations Telematics Module
Communications Control Module > Component Information > Diagrams > Audio Control Module (ACM)
Communications Control Module: Diagrams Audio Control Module (ACM)

Communications Control Module > Component Information > Diagrams > Audio Control Module (ACM) > Page 12
Communications Control Module: Diagrams In-Dash Computer

Communications Control Module: Diagrams In-Dash Computer Junction Box

Communications Control Module: Diagrams Telematics Module

Communications Control Module > Component Information > Service and Repair > Procedures
Communications Control Module: Procedures
Ford Work Solutions(TM) Self-Diagnostic Mode
In-Dash Computer Self-Diagnostic Mode
NOTE: It is normal for popping sounds to be heard in the speakers while the in-dash computer is
transitioning between modes. This is due to the power cycling of the in-dash computer.
1. Turn the in-dash computer on and navigate to the home screen.
2. Press and hold the power button and the phone button simultaneously for 10 seconds, until the
screen goes blank.
- The system automatically restarts in diagnostic mode.
3. The following diagnostic routines are available:

Communications Control Module > Component Information > Service and Repair > Procedures > Page 24
4. To exit the self-diagnostic mode, press and hold the power button for 10 seconds, until the
screen goes blank.
- The system automatically restarts in normal mode.
In-Dash Computer Software Level Check
1. Turn the in-dash computer on.
2. Press SETTINGS, then SYSTEM, then scroll down and select the VIEW icon next to the ABOUT
selection.
3. The following information (relevant to service) is displayed:
4. If needed, the in-dash computer software level can be compared with the latest software level by
checking the Ford Work Solutions(TM) consumer
website
Internet Connection Manager

2. Press SETTINGS, then SYSTEM SETTINGS, then scroll down and select the VIEW icon next to
the SPRINT CONNECTION MANAGER
selection.
Tool Link(TM) Diagnostic Test
2. Press the tool icon at the bottom RH corner of the screen (or press the tool hardkey).
3. Scroll down and select the TOOL LINK icon.
4. Select SERVICES, then STATUS.
Navigation Diagnostic Screen
2. Press the navigation icon at the top RH corner of the screen (or press the navigation hardkey).
3. Press the satellite status icon at the top LH corner of the screen.
4. A list of the current Global Positioning System (GPS) satellites detected is shown.
Communications Control Module: Removal and Replacement
Audio Control Module (ACM)

Removal
1. NOTE: Module configuration is only required when a new Audio Control Module (ACM) with
single CD is being installed.
Upload the ACM configuration information to the scan tool. For additional information, refer to
Programmable Module Installation (PMI) in Information Bus. See: Powertrain
Management/Computers and Control Systems/Information Bus/Testing and
Inspection/Programming and Relearning
2. NOTE: Use the special tools labeled N0.1 R for the right side and N0.1 L for the left side.
Using tool 4715-1 from the special tool kit, insert the special tools in the slots at all 4 corners of the
ACM with the lettering facing up until a click is heard.
3. While pushing outward on all 4 special tools, pull the ACM out then disconnect the electrical
connectors.
4. Remove the special tools from the ACM by pressing inward on the ACM retention tabs and then
pulling the special tools out.
Installation
1. Press the ACM in until a click is heard from each of the 4 retention tabs.
2. Download the configuration information to the ACM. For additional information, refer to PMI in
Information Bus. See: Powertrain

In-Dash Computer
In-Dash Computer
Center Instrument Panel Finish Panel
In-Dash Computer
Removal and Installation
1. Using a suitable tool (such as a flat-bladed trim removal tool), remove the instrument panel
center finish panel by prying it straight rearward.
2. Remove the 4 screws and the in-dash computer.
- Disconnect the electrical connectors.

3. To install, reverse the removal procedure.
Telematics Module
Telematics Module
Removal
1. Turn the ignition to OFF.
2. Remove the instrument panel fuse box cover.
3. Disconnect the telematics module electrical connector.
4. Remove the telematics module.
1. Remove the 2 screws.

2. Remove the bracket.
Installation
1. Position the telematics module and the bracket, and install the 2 screws.
2. Connect the telematics module electrical connector.
3. Install the instrument panel fuse box cover.
4. Initialize the telematics module.
1. Wait 5 minutes after the modem-antenna is installed.
2. Turn the ignition to RUN.
3. Wait 10 seconds.
4. Start the vehicle and run the engine for 30 seconds.
Tool Link(TM) Reader
1. Remove the in-dash computer. For additional information, refer to In-Dash Computer See:
In-Dash Computer.
2. Locate and cut the power feed wire for the Tool Link(TM) reader.
3. Remove the LH screw from the connector box bracket and remove the Tool Link(TM) reader
ground eyelet.
4. Remove the LH front and rear sill panels to access the Tool Link(TM) reader electrical harness.
5. Remove the 4 screws and the Tool Link(TM) reader.
1. Route the new power/ground feed electrical harness along the LH sill panel to the connector box
in the instrument panel.
2. Splice the power feed into the existing feed that was cut during the removal procedure.
3. Position the ground eyelet and install the LH connector box screw.
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Assist Control Module > Component Information > Locations > Page 33
Parking Assist Control Module: Diagrams

Assist Control Module > Component Information > Locations > Page 34
Parking Assist Control Module: Service and Repair
Parking Aid Module (PAM)
1. Remove the Central Junction Box (CJB) fuse panel cover.
2. If replacing the Parking Aid Module (PAM) only, proceed as follows:
- Remove the 2 bolts and the PAM.
3. If replacing the parking aid speaker only, proceed as follows:

- Disconnect the parking aid speaker electrical connector.
- Disengage the parking aid speaker clips.
- Remove the parking aid speaker.

Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice
Activation Module > Component Information > Locations
Voice Activation Module: Locations
Activation Module > Component Information > Locations > Page 38
Voice Activation Module: Diagrams
Voice Activation Module: Service and Repair
Speech Recognition Module (SRM)
1. Lower the glove compartment completely.
2. Remove the bolt and the Speech Recognition Module (SRM).
- Disconnect the electrical connector.
3. If removing the bracket, remove the 3 screws and the SRM bracket.
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations

Component Information > Testing and Inspection > Relays - Micro
Power Door Lock Relay: Testing and Inspection Relays - Micro
Component Information > Testing and Inspection > Relays - Micro > Page 47
Power Door Lock Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake Control
Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
Electronic Brake Control Module: Customer Interest Brakes - Front Brake Pads Wear Prematurely
TSB 11-2-11
02/07/11
PREMATURE WEAR-NEW FRONT BRAKE PADS
FORD: 2010-2011 Transit Connect
This article supersedes TSB 11-2-3 to update the Service Procedure, Part List and Service Labor
Time Standards.
ISSUE Some 2010 and 2011 Transit Connect vehicles may exhibit premature front disc brake pad
wear. A new brake pad has been released. Vehicles equipped with AdvanceTrac® Stability
Enhancement System will need to have the calibration updated, to match the new pad material.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Determine if the vehicle is equipped with AdvanceTrac(R) Stability Enhancement System. Turn
the ignition key to the ON position and look for the
AdvanceTrac(R) Traction Control light in the Instrument Cluster. (Figure 1)
2. Is vehicle equipped with AdvanceTrac(R) Stability Enhancement System?
a. Yes - Vehicle is equipped with AdvanceTrac(R) Stability Enhancement System, proceed to Step
3.
b. No - Vehicle is not equipped with AdvanceTrac(R) Stability Enhancement System, proceed to
Step 4.
3. Reprogram the ABS Module to the latest calibration using IDS release 71 .02A or later.
Calibration files may also be obtained at the website.
Proceed to Step 4.
4. Replace the front disc brake pads. Refer to Workshop Manual (WSM), Section 206-03.
5. Resur[ace/replace the front disc rotors, as necessary. Refer to Workshop Manual Section
206-03.
NOTE
BRAKE PADS AND ROTORS ARE COVERED FOR 12 MONTHS/28,968 KM (18,000 MILES)
ONLY.
NOTE
RSC CALIBRATION UPDATE IS COVERED FOR 36 MONTHS/57,936 KM (36,000 MILES) ONLY.
NOTE
BRAKE PADS AND ROTORS IN CANADA ARE COVERED 12 MONTHS/20,000 KM AND RSC
CALIBRATION IS COVERED 36 MONTHS/60,000 KM.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 59
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110211A 2010-2011 Transit 1.1 Hrs.
Connect: Replace The Front Brake Pads And Machine Both Front Disc Brake Rotors (Do Not Use
With Any Other Labor Operations)
110211B 2010-2011 Transit 0.8 Hr.
Connect: Replace The Front Brake Pads And Replace One Or Both Front Disc Brake Rotors (Do
Not Use With Any Other Labor Operations)
110211C 2010-2011 Transit 1.3 Hrs.
Connect: Replace The Front Brake Pads, Machine Both Front Disc Brake Rotors And Reprogram
The ABS Module (Do Not Use With Any Other Labor Operations)
110211D 2010-2011 Transit 1.0 Hr
Connect: Replace The Front Brake Pads, Replace One Or Both Front Disc Brake Rotors And
Reprogram The ABS Module (Do Not Use With Any Other Labor Operations)
110211E 2010-2011 Transit 0.3 Hr.
Connect: Reprogram The ABS Module (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 (OPERATIONS A AND B) 30
2C405 (OPERATIONS C - E) 34
Disclaimer
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
Electronic Brake Control Module: All Technical Service Bulletins Brakes - Front Brake Pads Wear
Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 65
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Control Module > Component Information > Technical Service Bulletins > Page 66
Electronic Brake Control Module: Locations
Electronic Brake Control Module: Diagrams

Electronic Brake Control Module: Service and Repair
Anti-Lock Brake System (ABS) Module
1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Hydraulic Control
Unit (HCU) See: Brakes and Traction
Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock

Brakes/Service and Repair.
2. Remove the 4 ABS module screws and the ABS module.
- To install, tighten to 2 Nm (18 lb-in).

Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations > Low Speed Fan Control Relay
Radiator Cooling Fan Motor Relay: Locations Low Speed Fan Control Relay
Relay > Component Information > Locations > Low Speed Fan Control Relay > Page 76
Radiator Cooling Fan Motor Relay: Locations High Speed Fan Control Relay
Relay > Component Information > Testing and Inspection > Relays - Micro
Radiator Cooling Fan Motor Relay: Testing and Inspection Relays - Micro
Relay > Component Information > Testing and Inspection > Relays - Micro > Page 79
Radiator Cooling Fan Motor Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Blower Motor Relay: Locations

Information > Testing and Inspection > Relays - Micro
Blower Motor Relay: Testing and Inspection Relays - Micro
Information > Testing and Inspection > Relays - Micro > Page 88
Blower Motor Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Compressor Clutch Relay: Locations
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Backup Lamp Relay: Locations
Backup Lamp Relay: Testing and Inspection Relays - Micro
Backup Lamp Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >
Courtesy Lamp Relay: Locations

Courtesy Lamp Relay: Testing and Inspection Relays - Micro
Courtesy Lamp Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Relay > Component Information > Locations
Daytime Running Lamp Relay: Locations
Daytime Running Lamp Relay: Testing and Inspection Relays - Micro
Daytime Running Lamp Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Low Beam Relay
Headlamp Relay: Locations Low Beam Relay
Component Information > Locations > Low Beam Relay > Page 123
Headlamp Relay: Locations High Beam Relay
Headlamp Relay: Testing and Inspection Relays - Micro
Headlamp Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Low Beam Relay >
Low Beam Relay: Locations

Low Beam Relay: Testing and Inspection Relays - Micro
Low Beam Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Relays - Micro
Power Distribution Relay: Testing and Inspection Relays - Micro
Distribution Relay > Component Information > Testing and Inspection > Relays - Micro > Page 142
Power Distribution Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Battery Junction Box (BJB)
Relay Box: Locations Battery Junction Box (BJB)
Component Information > Locations > Battery Junction Box (BJB) > Page 149
Component Information > Locations > Battery Junction Box (BJB) > Page 150
Relay Box: Locations Central Junction Box (CJB)
Component Information > Locations > Page 151
Relay Box: Diagrams

Component Information > Application and ID > Battery Junction Box (BJB)
Relay Box: Application and ID Battery Junction Box (BJB)
Component Information > Application and ID > Battery Junction Box (BJB) > Page 154
Relay Box: Application and ID Central Junction Box (CJB)

Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules -
Computers and Control Systems > Body Control Module > Component Information > Locations
Body Control Module: Locations
Computers and Control Systems > Body Control Module > Component Information > Locations > Page 162
Body Control Module: Diagrams

Body Control Module: Service and Repair
Generic Electronic Module (GEM)
Removal
NOTE: A new Generic Electronic Module (GEM) is delivered in a "manufacturing mode" with a
pre-set DTC. A successful configuration of the GEM, then a successful self-test including the
clearing of all DTCs is required in order to clear the manufacturing mode DTC. The manufacturing
mode DTC is:
- B2477 (Module Configuration Failure)
1. NOTE: This step is only necessary if the GEM is being replaced.
Upload the module configuration information from the GEM into the scan tool. For additional
information, refer to Information Bus.
2. NOTE: It may be easier to move/rotate the GEM to a lower position in order to access the 5
electrical connectors and their associated locking
mechanisms.
Remove the 2 screws and position the GEM to access the electrical connectors.
3. Disconnect the electrical connectors and remove the GEM.
Installation
1. Connect the electrical connectors.
2. NOTE: If the GEM is not being replaced, this is the last step that is necessary.
Position the GEM and install the 2 screws.

3. NOTE: When successful, this step provides the calibration necessary for the GEM operation and
clears DTC B2477. The clearing of this DTC
indicates the calibration data has been successfully downloaded to the GEM.
Download the GEM configuration information from the scan tool to the GEM. For additional
4. Carry out the GEM self-test (must include an on-demand self-test) and then repeat the self-test
to confirm all DTCs have been cleared.
Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description and
Operation
Electronic Throttle Control Module: Description and Operation
TORQUE-BASED ELECTRONIC THROTTLE CONTROL (ETC)
Overview
The torque-based ETC is a hardware and software strategy that delivers an engine output torque
(via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body
(ETB), the powertrain control module (PCM), and an accelerator pedal assembly to control the
throttle opening and engine torque.
Torque-based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and
later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque
during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM
and low manifold vacuum) while still delivering the performance and torque requested by the driver.
It also enables many fuel economy/emission improvement technologies such as variable camshaft
timing (VCT), which delivers same torque during transitions.
Torque-based ETC also results in less intrusive vehicle and engine speed limiting, along with
smoother traction control.
Other benefits of torque-based ETC are: -
eliminate cruise control actuators
- eliminate idle air control (IAC) valve
- better airflow range
- packaging (no cable)
- more responsive powertrain at altitude and improved shift quality
The ETC system illuminates a powertrain malfunction indicator (wrench) on the instrument cluster
(IC) when a concern is present. Concerns are accompanied by diagnostic trouble codes (DTCs)
and may also illuminate the malfunction indicator lamp (MIL).
Electronic Throttle Body (ETB)
The ETB has the following characteristics: -
The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2 wires).
- There are 2 designs: parallel and in-line. The parallel design has the motor under the bore parallel
to the plate shaft. The motor housing is integrated into the main housing. The in-line design has a
separate motor housing.
- An internal spring is used in both designs to return the throttle plate to a default position. The
default position is typically a throttle angle of 7 to 8 degrees from the hard stop angle.
- The closed throttle plate hard stop is used to prevent the throttle from binding in the bore. This
hard stop setting is not adjustable and is set to result in less airflow than the minimum engine
airflow required at idle.
- The required idle airflow is provided by the plate angle in the throttle body assembly. This plate
angle controls idle, idle quality, and eliminates the need for an IAC valve.
- There is one reference voltage and one signal return circuit between the PCM and the ETB. The
reference voltage and the signal return circuits are shared with the reference voltage and signal
return circuits used by the accelerator pedal position (APP) sensor. There are also 2 throttle
position (TP) signal circuits for redundancy. The redundant TP signals are required for increased
monitoring reasons. The first TP signal (TPS1-NS) has a negative slope (increasing angle,
decreasing voltage) and the second signal (TPS2-PS) has a positive slope (increasing angle,
increasing voltage). The TPS2-PS signal reaches a limit of approximately 4.5 volts at
approximately 45 degrees of throttle angle.
Accelerator Pedal Position (APP) Sensor
Depending on the application either a 2-track or 3-track APP sensor is used. For additional
information on the APP sensor, refer to Engine Control Components. See: Powertrain
Management/Computers and Control Systems/Description and Operation/Engine Control
Components
Electronic Throttle Control (ETC) System Strategy
The torque-based ETC strategy was developed to improve fuel economy and to accommodate
variable camshaft timing (VCT). This is possible by not coupling the throttle angle to the driver
pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver
demand) allows the powertrain control strategy to optimize fuel control and transmission shift
schedules while delivering the requested wheel torque.
The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain
control processor unit (CPU) and a separate monitoring processor. The primary monitoring function
is carried out by the independent plausibility checker (IPC) software, which resides on the main
processor. It is responsible for determining the driver-demanded torque and comparing it to an
estimate of the actual torque delivered. If the generated torque exceeds driver demand by a
specified amount, appropriate corrective action is taken.
Operation > Page 172
ETC System With A 3-Track APP Sensor Failure Mode Effects Management (Part 1)
ETC System With A 2-Track APP Sensor Failure Mode And Effects Management
Electronic Throttle Monitor Operation
APP and TP Sensor Inputs

Accelerator Pedal Position (APP) Sensor Check
Throttle Position (TP) Sensor Check
Electronic Throttle Actuator Control (TAC) Output
Electronic TAC Operation Check

Computers and Control Systems > Engine Control Module > Component Information > Locations
Engine Control Module: Locations
Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 178
Engine Control Module: Diagrams
Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures
Engine Control Module: Procedures
FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
Description
The EEPROM is contained in an integrated circuit internal to the powertrain control module (PCM).
The EEPROM contains the vehicle strategy including calibration information specific to the vehicle,
and is capable of being programmed or flashed repeatedly.
As part of the calibration there is an area referred to as the vehicle identification (VID) block. The
VID block is programmed when installing a new PCM as described under Programming the VID
Block for a Replacement PCM. Failure to carry out this procedure may generate DTC P1635 or
P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware
or parameter changes made to the vehicle since production. Failure to carry out this procedure
properly may generate DTC P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle
ratio is one of the main causes for DTC P1639. This is described under Making Changes to the VID
Block and also under Making Changes to the PCM Calibration. The VID block contains many items
used by the strategy for a variety of functions. Some of these items include the vehicle identification
number (VIN), octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the
presence of speed control, and 4-wheel drive electronic shift-on-the-fly (ESOF) versus manual
shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID
block are displayed on the scan tool.
When changing items in the VID block, the strategy places range limits on certain items such as
tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this
limit is reached, the scan tool displays a message indicating the need to flash the PCM again to
reset the VID block.
On selected vehicles equipped with permanent DTC reporting capabilities, neutral profile correction
should be learned after a PCM replacement in order to activate the misfire monitor. This can be
accomplished using the Misfire Monitor Neutral Profile Learn function on the scan tool.
Programming can be carried out by a local Ford dealer or any non-Ford facility. Refer to the scan
tool manufacturer's instruction manual for details.
Neutral Profile Correction
In order for the misfire detection system to function properly, any mechanical inaccuracies in the
crankshaft position (CKP) sensor must be learned by the PCM. This information is stored in
non-volatile memory (NVM) in the PCM. It is not cleared when the keep alive memory (KAM) is
reset.
Neutral profile learning is accomplished using the scan tool any time a PCM is replaced. It should
also be relearned any time the CKP sensor is replaced or major engine repairs have been
completed.
To determine if the neutral profile learning has been completed, check the MP_LRN parameter
identification (PID) using the scan tool. The PID should read YES if the neutral profile learning has
been completed. If the PID reads NO, complete the neutral profile learning prior to diagnosing any
misfire DTCs.
Programming the VID Block for a Replacement PCM
The VID block on a replacement PCM is blank and requires programming. There are two
procedures available. The first is an automatic data transfer from the old PCM to the new PCM, the
second is manual data entry into the new PCM.
Automatic data transfer is carried out if the old PCM is capable of communicating. This is done by
using a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored
data can be downloaded to the new PCM after it has been installed.
Carry out manual data entry if the old PCM is damaged or incapable of communicating. Remove
and install a new PCM. Using a compatible scan tool, select and carry out the module/parameter
programing, referring to the scan tool manufacturer's instruction manual. Make certain that all
parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile
equals 63,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF
may result in DTCs P1635 and P1639. You may be instructed to contact the As-Built Data Center
for the information needed to manually update the VID block with the scan tool. Contact the center
only if the old PCM cannot be used or the data is corrupt. For Ford and Lincoln Mercury
technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for
As-Built data listed under the Service Publications Index. Non-Ford technicians use the
Motorcraft(R) website at www.motorcraft.com. From the Motorcraft(R) home page, use the search
function to find the Module Programming or As-Built Data.
For Ford and Lincoln Mercury technicians, check the Programmable Module Installation link on the
PTS web site for quick Programmable Module data information by vehicle.
Making Changes to the VID Block
A programmed PCM may require changes to be made to certain VID information to accommodate
the vehicle hardware. Refer to Module Reprogramming on the scan tool.
Making Changes to the PCM Calibration
At certain times, the EEPROM needs to be completely reprogrammed. This is due to changes
made to the strategy or calibration after production or the need to reset the VID block because it
has reached its limit. Refer to PCM/Module Reprogramming on the scan tool.
Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures >
Page 189
Engine Control Module: Removal and Replacement
Powertrain Control Module (PCM)
Removal
1. NOTE: PCM installation DOES NOT require new keys or programming of keys, only a
Parameter Reset of the Passive Anti-Theft System
(PATS).
Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Information
Bus.
2. Remove the Air Cleaner (ACL) outlet pipe and the ACL assembly. For additional information,
refer to Fuel Delivery and Air Induction.
3. Disconnect the 3 PCM electrical connectors.
4. Remove the 2 bolts and the PCM.
Installation
1. Install the PCM and the 2 bolts.
- Tighten to 8 Nm (71 lb-in).

2. Connect the 3 PCM electrical connectors.
3. Install the ACL outlet pipe and the ACL assembly. For additional information, refer to Fuel
Delivery and Air Induction.
4. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure.
For additional information, refer to Information Bus.
5. Reprogram the PATS. Carry out the Parameter Reset procedure. For additional information,
refer to Antitheft and Alarm Systems. See:
Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and

Inspection/Programming and Relearning/Passive Anti-Theft System (PATS) Parameter Reset
Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection
> Relays - Micro
Main Relay (Computer/Fuel System): Testing and Inspection Relays - Micro
> Relays - Micro > Page 195
Main Relay (Computer/Fuel System): Testing and Inspection Relay - Mini ISO
Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Relays - Micro
Fuel Pump Relay: Testing and Inspection Relays - Micro
Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Relays - Micro >
Page 204
Page 205
Fuel Pump Relay: Testing and Inspection Relay - Mini ISO
Page 206
Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection >
Relays - Micro
Relays - Micro > Page 212
Ignition System > Ignition Relay > Component Information > Locations
Ignition Relay: Locations
Ignition System > Ignition Relay > Component Information > Testing and Inspection > Relays - Micro
Ignition Relay: Testing and Inspection Relays - Micro
Ignition System > Ignition Relay > Component Information > Testing and Inspection > Relays - Micro > Page 221
Ignition Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Air Bag Control Module: Locations
Air Bag Control Module: Diagrams
Air Bag Control Module: Service and Repair
Restraints Control Module (RCM)
Removal
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: 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.
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module
(RCM) fuse is removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults
before releasing the vehicle to the customer.
1. Carry out the steps necessary to prepare for Programmable Module Installation (PMI). For
additional information, refer to Information Bus.
2. Depower the SRS. For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering See: Body and
Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and

Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and Repowering
in the General Procedures.
3. Remove the selector lever. For additional information, refer to Automatic

Transmission/Transaxle.
4. Remove the 4 nuts and selector lever stabilizer.
5. Disconnect the large RCM electrical connector.
1. Pinch the thumb tab and pivot the Connector Position Assurance (CPA) all the way back until it
stops.
2. Pull out and disconnect the large RCM electrical connector.

6. Disconnect the small RCM electrical connector.
7. Remove the 3 bolts and the RCM.
Installation
1. 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
Install the RCM and the 3 bolts. -
Tighten to 9 Nm (80 lb-in).
2. Connect the small RCM electrical connector.
3. Make sure the large RCM electrical connector position assurance lever is in the FULL RELEASE
position before attempting to connect the
connector.
4. NOTICE: Placing the large Restraints Control Module (RCM) electrical wiring connector into the
RCM at an angle can cause bad
electrical connections and damage components.
Position the large RCM electrical wiring connector into the RCM. -
NOTICE: Do not push the connector to where the lever pivots and seats itself. Light pressure is
needed to get the connector into position on the Restraints Control Module (RCM) before using the
lever to fully seat the connector.
With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a
subtle audible click is heard and a slight resistance is felt.
5. Connect the large RCM electrical connector.

- Using the CPA, pivot it toward the RCM, drawing the connector into the RCM. -
Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
6. Install the selector lever stabilizer and 4 nuts.
7. Install the selector lever. For additional information, refer to Automatic Transmission/Transaxle.
8. Repower the SRS. Do not prove out the SRS at this time. For additional information, refer to
Supplemental Restraint System (SRS) Depowering
and Repowering See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air
Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures.
9. When installing a new RCM, carry out the steps necessary to complete PMI. For additional
10. Prove out the SRS as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the switch back to ON and monitor
the air bag warning indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present, the
air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur
until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON
position. This is the time required for the RCM to complete the testing of the SRS. If the air bag
indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps.
If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired.
Clear all CMDTCs from the RCM and Occupant Classification System Module (OCSM).
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations
Seat Occupant Classification Module - Air Bag: Locations
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 237
Seat Occupant Classification Module - Air Bag: Diagrams

Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Starter Relay: Locations
Starter Relay: Testing and Inspection Relays - Micro
Starter Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules -
Wheels and Tires > Tire Pressure Module > Component Information > Locations
Tire Pressure Module: Locations
Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 252
Tire Pressure Module: Diagrams

Tire Pressure Module: Service and Repair
Tire Pressure Monitoring System (TPMS) Module
Removal
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: The Tire Pressure Monitoring System (TPMS)/Vehicle Security Module (VSM) is also
identified as the VSM.
NOTE: Prior to the replacement of the TPMS/VSM, it is necessary to upload the module
configuration information to a scan tool. This information must be downloaded into the new
TPMS/VSM after installation. For additional information, refer to Information Bus.
NOTE: The steps included in this procedure are critical to restoring the TPMS to normal operation.
A new TPMS/VSM is delivered in a manufacturing mode with 6 pre-set DTCs related to the TPMS.
To clear the DTCs, successful configuration of the TPMS/VSM must occur, followed by successful
TPMS sensor training, and a successful self-test. The DTCs are as follows:
- B2477 - Module Configuration Failure
- B2868 - Left Front Tire Pressure Sensor Fault
- B2869 - Right Front Tire Pressure Sensor Fault
- B2870 - Right Rear Tire Pressure Sensor Fault
- B2871 - Left Rear Tire Pressure Sensor Fault
- C2780 - ECU in Manufacturer Sub-State
1. NOTE: This step is necessary only if the TPMS/VSM is being replaced.
Upload the module configuration information from the TPMS/VSM. For additional information, refer
to Information Bus.
2. Open the glove compartment door and while pushing in on the glove compartment tabs, position
the glove compartment downwards.
3. Disconnect the Accessory Protocol Interface Module (APIM) electrical connector.
4. Disconnect the 2 TPMS/VSM electrical connectors.
5. Remove the 2 nuts and the TPMS/VSM.
Installation
1. Position the TPMS/VSM and install the 2 nuts.
- Tighten to 6 Nm (53 lb-in). -
Connect the 2 electrical connectors.
2. Connect the APIM electrical connector.
3. While pushing in on the glove compartment tabs, position the glove compartment upwards and
close the glove compartment door.
4. NOTE: When successful, this step provides the calibration necessary for the TPMS/VSM
operation and will clear DTC B2477. The clearing of
this DTC indicates the calibration data has been successfully downloaded to the new TPMS/VSM.
Download the TPMS/VSM configuration information from the scan tool. For additional information,
refer to Information Bus.
5. NOTE: When successful, this step clears DTCs B2868, B2869, B2870 and B2871. The clearing
of these DTCs indicates the TPMS/VSM has
recognized the tire pressure sensors during the training procedure.

Train the tire pressure sensors. For additional information, refer to Tire Pressure Monitoring
System (TPMS) Sensor Training See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes.
6. NOTE: DTC C2780 will not clear if any other DTCs are present in the TPMS/VSM. When
successful, this step will clear DTC C2780.
Carry out the TPMS/VSM self-test (must include an on-demand self test) and then repeat the
self-test to confirm all DTCs have been cleared.
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Heated Glass Element Relay: Locations

Heated Glass Element Relay: Testing and Inspection Relays - Micro
Heated Glass Element Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Power Window Relay: Locations
Power Window Relay: Diagrams

Power Window Relay: Testing and Inspection Relays - Micro
Power Window Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Wiper Relay: Locations

Wiper Relay: Testing and Inspection Relays - Micro
Wiper Relay: Testing and Inspection Relay - Mini ISO
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Left
Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 291
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Outer Right
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Left
Parking Assist Distance Sensor: Locations Parking Aid Sensor, Inner Right
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor, Outer Left
Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 296
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor, Outer Right
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor, Inner Left
Parking Assist Distance Sensor: Diagrams Parking Aid Sensor, Inner Right
Assist Distance Sensor > Component Information > Diagrams > Page 303
Parking Assist Distance Sensor: Service and Repair
Parking Aid Sensor
Removal
1. Remove the rear bumper. For additional information, refer to Bumper.
2. Disconnect the electrical connector.
3. With a suitable tool (such as a flat-bladed screwdriver), gently pry the retaining tabs to remove
the parking aid sensor(s).
- Remove the parking aid sensor(s) from the rear bumper.
5. After installing the sensor(s), use the scan tool to verify that the parking aid sensor PIDs read no
object present, 255 cm (8.4 ft). If the parking aid
sensor does not respond correctly, refer to Parking Aid in the Diagnosis and Testing See:
Accessories and Optional Equipment/Collision Avoidance and Parking Assist Systems/Testing and
Inspection.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Position Switch >
Component Information > Locations > Sliding Door Contact Switch, Right
Door Position Switch: Locations Sliding Door Contact Switch, Right
Component Information > Locations > Sliding Door Contact Switch, Right > Page 309
Door Position Switch: Locations Sliding Door Contact Switch, Left
Door Position Switch: Locations Sliding Door Ajar Switch, Left
Door Position Switch: Locations Sliding Door Ajar Switch, Right
Component Information > Diagrams > Sliding Door Contact Switch, Right
Door Position Switch: Diagrams Sliding Door Contact Switch, Right
Component Information > Diagrams > Sliding Door Contact Switch, Right > Page 314
Door Position Switch: Diagrams Sliding Door Contact Switch, Left
Door Position Switch: Diagrams Sliding Door Ajar Switch, Left
Door Position Switch: Diagrams Sliding Door Ajar Switch, Right
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Power Mirror Switch: Locations
Power Mirror Switch: Diagrams
Power Mirror Switch: Testing and Inspection
Power Mirror Switch: Service and Repair
Exterior Mirror Control Switch
1. Remove the exterior mirror control switch.
- Using a non-marring tool, pry upward on the exterior mirror control switch at the location shown.
2. Disconnect the exterior mirror control switch electrical connector.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations
ABS Sensor Block: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > ABS Sensor
Block > Component Information > Locations > Page 333
ABS Sensor Block: Diagrams

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Service and Repair
Acceleration/Deceleration Sensor: Service and Repair
Stability Control Sensor Cluster
NOTE: When installing a new stability control sensor cluster, the IVD Initialization sequence must
be carried out. Follow the scan tool directions for the calibration procedures.
1. Remove the floor console. For additional information, refer to Instrument Cluster / Carrier &/or
Interior Moulding / Trim.
2. Disconnect the stability control sensor cluster electrical connector.
3. Remove the 2 stability control sensor cluster bracket bolts and the stability control sensor
cluster.

- Carry out the IVD Initialization sequence for all 4 stability control sensors (roll rate, yaw rate,
lateral acceleration sensor, longitudinal acceleration sensor). Follow the scan tool directions.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Level Sensor/Switch > Component Information > Locations > Page 340
Brake Fluid Level Sensor/Switch: Diagrams
Level Sensor/Switch > Component Information > Locations > Page 341
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Warning Switch > Component Information > Locations > Page 345
Parking Brake Warning Switch: Diagrams
Warning Switch > Component Information > Locations > Page 346
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Steering Angle Sensor: Service and Repair
Steering Angle Sensor Module (SASM)
Removal
1. Remove the clockspring. For additional information, refer to Restraint Systems.
2. Disconnect the Steering Angle Sensor Module (SASM) electrical connector.
3. Release the locking tabs and remove the SASM from the clockspring.
Installation
1. If the arrow on the SASM ring and the arrow on the sensor housing are misaligned and/or the
straight-ahead position of the sensor is not known,
follow these steps to align the sensor prior to installing the sensor:
1. Orient the front wheels in the straight-ahead position.

2. Connect the SASM electrical connector.
3. Carefully rotate the sensor clockwise until it stops.
4. Rotate the sensor counterclockwise two and one-half turns.
5. Using the scan tool, read the SASM position PID (STEER_ANGL). The PID should read
approximately 0 degrees. If not, repeat the
procedure.
6. Disconnect the SASM electrical connector.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair > Page 350
2. NOTE: Slight rotation of the SASM ring is allowed to align the 2 arrows.
Make sure the sensor ring arrow is lined up with the SASM housing arrow as shown and position
the sensor into the multifunction switch housing.
4. Install the SASM to the clockspring. Make sure that the tabs on the inner ring of the SASM align
with the notches on the clockspring and that the
locking tabs on the clockspring hold the SASM to the clockspring securely.
5. Install the clockspring. For additional information, refer to Restraint Systems.
- If the SASM was aligned using the scan tool, DTCs may be present in the Restraints Control
Module (RCM). Using the scan tool, clear the DTCs in the RCM.
6. Calibrate the ABS module.
- Carry out the IVD Initialization sequence for the steering angle sensor. Follow the scan tool
directions.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Front
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 355
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Front
Wheel Speed Sensor: Locations Wheel Speed Sensor, Left Rear
Wheel Speed Sensor: Locations Wheel Speed Sensor, Right Rear
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front
Wheel Speed Sensor: Diagrams Wheel Speed Sensor, Left Front

Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 360
Wheel Speed Sensor: Diagrams Wheel Speed Sensor, Right Front

Wheel Speed Sensor: Diagrams Wheel Speed Sensor, Left Rear
Wheel Speed Sensor: Diagrams Wheel Speed Sensor, Right Rear
Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Front
Wheel Speed Sensor - Front
1. Remove the wheel and tire. For additional information, refer to Wheels and Tires.
2. Remove the wheel speed sensor bolt.
3. Disconnect the wheel speed sensor electrical connector.

- Remove the sensor by detaching the pin-type retainer and pulling the sensor grommets out of the
clips.

Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 367
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear
Wheel Speed Sensor - Rear
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle
Jacking and Lifting.
clips.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Radiator Cooling Fan Speed
Sensor > Component Information > Description and Operation
Radiator Cooling Fan Speed Sensor: Description and Operation
ENGINE CONTROL COMPONENTS
Fan Speed Sensor (FSS)
The FSS is a Hall-effect sensor that measures the cooling fan clutch speed by generating a
waveform with a frequency proportional to the fan speed. If the cooling fan clutch is moving at a
relatively low speed, the sensor produces a signal with a low frequency. As the cooling fan clutch
speed increases, the sensor generates a signal with a higher frequency. The PCM uses the
frequency signal generated by the FSS as a feedback for closed loop control of the cooling fan
clutch. For additional information on the cooling fan clutch, refer to the Cooling Fan Clutch.
Cooling Fan Clutch With FSS

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description
and Operation > Cylinder Head Temperature (CHT) Sensor
Coolant Temperature Sensor/Switch (For Computer): Description and Operation Cylinder Head
Temperature (CHT) Sensor
Cylinder Head Temperature (CHT) Sensor
The CHT sensor is a thermistor device in which resistance changes with the temperature. The
electrical resistance of a thermistor decreases as temperature increases, and the resistance
increases as the temperature decreases. The varying resistance affects the voltage drop across
the sensor terminals and provides electrical signals to the PCM corresponding to temperature.
The CHT sensor is installed in the cylinder head and measures the metal temperature. The CHT
sensor provides complete engine temperature information and is used to infer coolant temperature.
If the CHT sensor conveys an overheating condition to the PCM, the PCM initiates a fail-safe
cooling strategy based on information from the CHT sensor. A cooling system concern, such as low
coolant or coolant loss, could cause an overheating condition. As a result, damage to major engine
components could occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM
prevents damage by allowing air cooling of the engine and limp home capability. For additional
information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy. See: Powertrain
Management/Computers and Control Systems/Description and Operation/Powertrain Control
Software
Typical CHT Sensor

Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description
and Operation > Cylinder Head Temperature (CHT) Sensor > Page 377
Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant
Temperature (ECT) Sensor
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases, and the resistance
increases as the temperature decreases. The varying resistance changes the voltage drop across
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a

voltage divider network so varying the resistance of the passive sensor causes a variation in total
current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor
determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage
minus the voltage drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The PCM uses the ECT input for fuel
control and for cooling fan control. There are 3 types of ECT sensors; threaded, push-in, and
twist-lock. The ECT sensor is located in an engine coolant passage.
Typical Thread-Type ECT Sensor

Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Engine Temperature Sensor: Locations
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 381
Engine Temperature Sensor: Diagrams
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page 382
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature (CHT) Sensor
Software
Typical CHT Sensor

Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature (CHT) Sensor > Page 385
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor


Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation > Page
386
Engine Temperature Sensor: Service and Repair
1. Pull back the Cylinder Head Temperature (CHT) sensor cover and disconnect the electrical
connector.
2. Remove the CHT sensor.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Locations
Brake Switch (Cruise Control): Locations
> Component Information > Locations > Page 391
Brake Switch (Cruise Control): Diagrams
> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch
Brake Pedal Position (BPP) Switch
The BPP switch is sometimes referred to as the stoplamp switch. The BPP switch provides a signal
to the PCM indicating the brakes are applied. The BPP switch is normally open and mounted on
the brake pedal support. Depending on the vehicle application the BPP switch can be hardwired as
follows: -
to the PCM supplying battery positive (B+) voltage when the brake pedal is applied.
- to the anti-lock brake system (ABS) module, or lighting control module (LCM), the BPP signal is
then broadcast over the network to be received by the PCM.
- to the ABS traction control/stability assist module. The ASS module interprets the BPP switch
input along with other ABS inputs and generates an output called the driver brake application
(DBA) signal. The DBA signal is then sent to the PCM and to other BPP signal users.
Typical BPP Switch

> Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 395
Brake Switch (Cruise Control): Description and Operation Brake Pressure Switch
Brake Pressure Switch
The brake pressure switch is used for vehicle speed control deactivation. A normally closed switch
supplies battery positive (B+) voltage to the PCM when the brake pedal is not applied. When the
brake pedal is applied, the normally closed switch opens and power is removed from the PCM.
On some applications the normally closed brake pressure switch, along with the normally open
BPP switch, are used for a brake rationality test within the PCM. The PCM misfire monitor profile
learn function may be disabled if a brake switch concern occurs. If one or both brake pedal inputs
to the PCM is not changing states as expected, a diagnostic trouble code (DTC) is set by the PCM
strategy.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Description and Operation
Clutch Switch: Description and Operation
Clutch Pedal Position (CPP) Switch
The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a
low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low
through the signal return (SIG RTN) circuit. The CPP input to the PCM is used to detect a reduction
in engine load. The PCM uses the load information for mass air flow and fuel calculations.
Typical Cluch Pedal Position (CPP) Switch

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair
Cruise Control Switch: Service and Repair
Cruise Control Switch
1. Remove the driver air bag module. For additional information, refer to Restraint Systems.
2. Disconnect the cruise control switches electrical connector.
4. Remove the cruise control switches.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Oil Pressure Sender: Locations
Information > Locations > Page 406
Oil Pressure Sender: Diagrams
Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch
Oil Pressure Sender: Service and Repair Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil
Pressure (EOP) Switch
Engine Lubrication Components - Exploded View

Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch
Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch > Page
410
Oil Pressure Sender: Service and Repair Engine Oil Pressure (EOP) Switch
Engine Oil Pressure (EOP) Switch
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch.
4. NOTE: Apply thread sealant to the EOP switch threads.
To install, reverse the removal procedure.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation
Oil Temperature Sensor/Switch: Description and Operation
Engine Oil Temperature (EOT) Sensor
The EOT sensor is a thermistor device in which resistance changes with temperature. The
electrical resistance of a thermistor decreases as the temperature increases and the resistance

voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor
The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into
the engine oil lubrication system. The PCM uses the EOT sensor input in conjunction with other
PCM inputs to determine oil degradation.
The PCM uses EOT sensor input to initiate a soft engine shutdown to prevent engine damage from
occurring as a result of high oil temperatures. Whenever engine RPM exceeds a calibrated level for
a certain period of time, the PCM begins reducing power by disabling engine cylinders.
On VCT applications, the PCM uses the EOT sensor input to adjust the VCT control gains and
logic for camshaft timing.
Typical EOT Sensor

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Air Conditioning Switch: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Air Conditioning Switch: Diagrams

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch,
HVAC > Component Information > Locations
Air Door Position Sensor / Switch: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Door Position Sensor / Switch,
HVAC > Component Information > Locations > Page 422
Air Door Position Sensor / Switch: Diagrams

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Technical Service Bulletins > Customer Interest for Blower Motor Switch: > 09-19-6 > Oct > 09 > A/C - Blower
Motor Won't Turn OFF/One Speed Inop.
Blower Motor Switch: Customer Interest A/C - Blower Motor Won't Turn OFF/One Speed Inop.
TSB 09-19-6
10/05/09
HEATER BLOWER FAN SWITCH - CONTINUOUS OPERATION / INOPERATIVE ON ONE

SPEED
FORD: 2010 Transit Connect
ISSUE Some 2010 Transit Connect vehicles may exhibit a heater blower fan motor continuously
operating, or inoperative on one speed setting. This may be due to a wire chafe in the 14401
harness, behind the center console.
SERVICE PROCEDURE
1. Lift the park brake lever upward.
2. Place the selector lever in the neutral position.
3. Remove the selector lever trim panel in the following sequence.
a. Lift the rear of the panel upward, releasing the rear retaining clips.
b. Pull the panel toward the rear of the vehicle releasing the front retaining clips.
4. Confirm touch condition between heater blower switch wiring and instrument panel (IP) bracket.
(Figure 1)
5. Repair any chafed wires using approved splicing methods. Refer to Wiring Diagram (WD), Cell
5.
Motor Won't Turn OFF/One Speed Inop. > Page 431
6. Pull the heater blower wiring away from the IP bracket and secure to the large bundle of wire
(Figures 2 and 3)
7. Tighten tie strap and verify that the heater wiring is sufficiently spaced away from the IP bracket
(Figure 4)
8. Install selector trim panel.
091906A 2010 Transit Connect: 0.2 Hr.
Inspect And Reroute Wire Harness Following Service Procedure (Do Not Use With Any Other
Labor Operations)
091906B 2010 Transit Connect: 0.5 Hr.
Inspect And Reroute Wire Harness Following Service Procedure Includes Time To Repair Chafed
Wires (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor Switch: > 09-19-6 > Oct > 09 >
A/C - Blower Motor Won't Turn OFF/One Speed Inop.
Blower Motor Switch: All Technical Service Bulletins A/C - Blower Motor Won't Turn OFF/One
Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
A/C - Blower Motor Won't Turn OFF/One Speed Inop. > Page 438
(Figures 2 and 3)
(Figure 4)
Labor Operations)
A/C - Blower Motor Won't Turn OFF/One Speed Inop. > Page 439
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Information > Technical Service Bulletins > Page 440
Blower Motor Switch: Locations
Blower Motor Switch: Diagrams
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
HVAC > Component Information > Diagrams > A/C Compressor Cycling Switch
Refrigerant Pressure Sensor / Switch: Diagrams A/C Compressor Cycling Switch
HVAC > Component Information > Diagrams > A/C Compressor Cycling Switch > Page 448
Refrigerant Pressure Sensor / Switch: Diagrams A/C Pressure Transducer
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Dimmer Switch: Service and Repair
Instrument Panel Dimmer Switch
1. Remove the fuse access cover.
2. NOTE: The instrument panel dimmer switch is removed by reaching through the fuse cover
opening and pushing it from behind.
Release the clips and remove the instrument panel dimmer switch.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Door Ajar Switch, Left Front
Door Switch: Locations Door Ajar Switch, Left Front
Information > Locations > Door Ajar Switch, Left Front > Page 459
Door Switch: Locations Door Ajar Switch, Right Front
Door Switch: Locations Door Ajar Switch, Rear Doors
Information > Diagrams > Door Ajar Switch, Left Front
Door Switch: Diagrams Door Ajar Switch, Left Front

Information > Diagrams > Door Ajar Switch, Left Front > Page 463
Door Switch: Diagrams Door Ajar Switch, Right Front

Door Switch: Diagrams Door Ajar Switch, Rear Doors

Information > Diagrams > Page 465
Door Switch: Service and Repair
Door Ajar Switch - Sliding
1. Remove the C-pillar trim panel.
2. Disconnect the sliding door ajar switch electrical connector.
3. Release the tabs and remove the sliding door ajar switch.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Fuel Gauge Sender: Locations
Fuel Gauge Sender: Diagrams
Component Information > Description and Operation > Fuel Pump (FP) Module
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module
Fuel Pump (FP) Module
The FP module contains the fuel pump and sender assembly. The fuel pump is located inside the
FP module reservoir and supplies fuel through the FP module manifold to the engine and FP
module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve
located in the manifold outlet maintains system pressure when the fuel pump is not energized. A
flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the
fuel pump during the initial fill.
Typical Electronic Returnless FP Module
Typical Mechanical Returnless FP Module

Component Information > Description and Operation > Fuel Pump (FP) Module > Page 473
Fuel Gauge Sender: Description and Operation Fuel Pump (FP) Module and Reservoir
Fuel Pump (FP) Module and Reservoir
The FP module is mounted inside the fuel tank in a reservoir. The pump has a discharge check
valve that maintains the system pressure after the ignition has been turned off to minimize starting
concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low
tank fill levels.
Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View
Fuel Gauge Sender: Service and Repair Fuel Tank and Filler Pipe - Exploded View
Fuel Tank and Filler Pipe - Exploded View
Fuel Tank Heat Shields and Retainers
Fuel Tank and Filler Pipe

Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 476
Fuel Pump (FP) Module, Fuel Tank and Straps
Fuel Gauge Sender: Service and Repair Fuel Pump Module
Fuel Pump Module
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in
serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the
event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition
sources. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system
remains under high pressure, even when the engine is not running. Failure to follow this instruction
may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Powertrain
Management/Fuel Delivery and Air Induction/Fuel
Tank/Service and Repair/Removal and Replacement/Fuel Tank.
2. NOTE: Clean the Fuel Pump (FP) connections, couplings, flange surfaces and the immediate
surrounding area of any dirt or foreign material.
Disconnect the fuel jumper tube-to-FP module quick connect coupling. For additional information,
3. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the Fuel Pump
(FP) module when removing the lock
ring.
Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.
4. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float
arm.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Completely remove the FP module from the fuel tank.
5. NOTE: Inspect the mating surfaces of the FP module flange and the fuel tank O-ring seal contact
surfaces. Do not polish or adjust the O-ring seal
contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the
O-ring seal contact area is bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the new FP module O-ring seal.
Remove and discard the FP module O-ring seal.
- Install a new FP module O-ring seal.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Switch > Component Information > Locations > Page 483
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Backup Lamp Switch: Locations
Backup Lamp Switch: Diagrams
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Brake Light Switch: Locations
Brake Light Switch: Diagrams
Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
Brake Light Switch: Description and Operation Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 498
Brake Light Switch: Description and Operation Brake Pressure Switch
strategy.
Component Information > Description and Operation > Page 499
Brake Light Switch: Service and Repair
Stoplamp Switch
NOTICE: Do not press the brake pedal when installing or removing the stoplamp switch or damage
to the stoplamp switch may occur.
1. Disconnect the stoplamp switch electrical connector.
2. Rotate the stoplamp switch clockwise 45 degrees and remove the stoplamp switch.
3. NOTE: The stoplamp switch is self-adjusting. Do not press the brake pedal during installation.
Initial installation of the stoplamp switch allows
for one adjustment only. If additional adjustments are necessary, install a new stoplamp switch.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Door Ajar Switch, Left Front
Component Information > Locations > Door Ajar Switch, Left Front > Page 504
Component Information > Locations > Door Ajar Switch, Left Front > Page 505
Component Information > Diagrams > Door Ajar Switch, Left Front

Component Information > Diagrams > Door Ajar Switch, Left Front > Page 508

Component Information > Diagrams > Door Ajar Switch, Left Front > Page 509

Component Information > Diagrams > Page 510

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Hazard Warning Switch: Locations
Hazard Warning Switch: Diagrams
Hazard Warning Switch: Service and Repair
Hazard Flasher Lamp Switch
1. Pull the upper center instrument panel trim panel rearward and then up to separate it from the
instrument panel.
2. NOTE: Use a suitable tool (such as a pocket screwdriver) to release the tabs.
Accessing from above, release the tabs and remove the hazard flasher lamp switch.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Headlamp Dimmer Switch: Locations
Headlamp Dimmer Switch: Diagrams
Headlamp Dimmer Switch: Testing and Inspection
Headlamp Dimmer Switch: Service and Repair
Steering Column Multifunction Switch
All vehicles
1. Remove the steering column opening trim panel. For additional information, refer to the
Instrument Panel - Exploded View in Instrument Cluster /
Carrier &/or Interior Moulding / Trim.
2. Remove the upper and lower steering column shrouds. For additional information, refer to
Steering Column.
LH multifunction switch only
3. Disconnect the LH multifunction switch electrical connector.
4. Remove the 2 LH multifunction switch screws and the multifunction switch.
RH multifunction switch only
5. Disconnect the RH multifunction switch electrical connector.
6. Remove the 2 RH multifunction switch screws and the multifunction switch.

All vehicles

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Headlamp Switch: Locations
Headlamp Switch: Diagrams
Headlamp Switch: Testing and Inspection
Headlamp Switch: Service and Repair
Headlamp Switch
2. NOTE: The headlamp switch is removed by reaching through the fuse cover opening and
pushing it from behind.
Release the clips and remove the headlamp switch.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Horn Switch: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Turn Signal Switch: Locations
Turn Signal Switch: Diagrams
Turn Signal Switch: Testing and Inspection
Turn Signal Switch: Service and Repair
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 551
Accelerator Pedal Position Sensor: Diagrams

Page 552
Accelerator Pedal Position Sensor: Description and Operation
The APP sensor is an input to the powertrain control module (PCM) and used to determine the
amount of torque requested by the operator. Depending on the application, either a 2-track or
3-track APP sensor is used.
2-Track APP Sensor
There are 2 pedal position signals in the sensor. Both signals, APP and APP2, have a positive
slope (increasing angle, increasing voltage), but are offset and increase at different rates. The 2
pedal position signals make sure the PCM receives a correct input even if 1 signal has a concern.
The PCM determines if a signal is incorrect by calculating where it should be, inferred from the
other signals. If a concern is present with one of the circuits the other input is used. There are 2
reference voltage circuits, 2 signal return circuits, and 2 signal circuits (a total of 6 circuits and pins)
between the PCM and the APP sensor assembly. The pedal position signal is converted to pedal
travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts,
which is the input to the torque based strategy. For additional information, refer to Torque Based
Electronic Throttle Control (ETC). See: Powertrain Management/Computers and Control
Systems/Electronic Throttle Control Module/Description and Operation
Typical 2-Track APP Sensor
3-Track APP Sensor
There are 3 pedal position signals in the sensor. Signal 1, APP, has a negative slope (increasing
angle, decreasing voltage) and signals 2 and 3, APP2 and APP3, both have a positive slope
(increasing angle, increasing voltage). During normal operation, APP is used as the indication of
pedal position by the strategy. The 3 pedal position signals make sure the PCM receives a correct
input even if one signal has a concern. The PCM determines if a signal is incorrect by calculating
where it should be, inferred from the other signals. If a concern is present with one of the circuits
the other inputs are used. The pedal position signal is converted to pedal travel degrees (rotary
angle) by the PCM. The software then converts these degrees to counts, which is the input to the
torque based strategy. There are 2 reference voltage circuits, 2 signal return circuits, and 3 signal
circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly.

Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Air Flow Meter/Sensor: Locations
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 556
Air Flow Meter/Sensor: Diagrams

Air Flow Meter/Sensor: Description and Operation

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

Typical Drop-in MAF Sensor

Air Flow Meter/Sensor: Service and Repair
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 MAF sensor screws and the MAF sensor.

Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and
Operation
Barometric Pressure Sensor: Description and Operation
Barometric Pressure (BARO) Sensor
The BARO sensor directly measures barometric pressure to estimate the exhaust back pressure.
Exhaust back pressure influences speed density based air charge computation. The BARO sensor
is mounted directly to the PCM circuit board.
Switches - Computers and Control Systems > Brake Pressure Switch > Component Information > Description and
Operation > Brake Pedal Position (BPP) Switch
Brake Pressure Switch: Description and Operation Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

Operation > Brake Pedal Position (BPP) Switch > Page 567
Brake Pressure Switch: Description and Operation Brake Pressure Switch
strategy.
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor: Locations
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 571
Camshaft Position Sensor: Diagrams
Camshaft Position Sensor: Description and Operation
Camshaft Position (CMP) Sensor
The CMP sensor detects the position of the camshaft. The CMP sensor identifies when piston
number 1 is on its compression stroke. A signal is then sent to the PCM and used for synchronizing
the sequential firing of the fuel injectors. Coil on plug (COP) ignition applications use the CMP
signal to select the correct ignition coil to fire.
Vehicles with 2 CMP sensors are equipped with variable camshaft timing (VCT). The second
sensor is used to identify the position of the camshaft on bank 2.
There are 2 types of CMP sensors: the 2-pin variable reluctance type sensor and the 3-pin
Hall-effect type sensor.
Typical Variable Reluctance CMP Sensor
Typical Hall-effect CMP Sensor

Camshaft Position Sensor: Service and Repair
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
3. NOTE: Lubricate the O-ring with clean engine oil.

Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation

Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Description and Operation > Cylinder Head Temperature (CHT) Sensor
Software
Typical CHT Sensor

Information > Description and Operation > Cylinder Head Temperature (CHT) Sensor > Page 582


Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
586
Crankshaft Position Sensor: Diagrams
587
588
Crankshaft Position Sensor: Description and Operation
Crankshaft Position (CKP) Sensor
The CKP sensor is a magnetic transducer mounted on the engine block adjacent to a pulse wheel
located on the crankshaft. By monitoring the crankshaft mounted pulse wheel, the CKP is the
primary sensor for ignition information to the PCM. The pulse wheel has a total of 35 teeth spaced
10 degrees apart with 1 empty space for a missing tooth. The 6.8L 10-cylinder pulse wheel has 39
teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the
pulse wheel, the CKP sensor signal indicates crankshaft position and speed information to the
PCM. By monitoring the missing tooth, the CKP sensor is also able to identify piston travel in order
to synchronize the ignition system and provide a way of tracking the angular position of the
crankshaft relative to a fixed reference for the CKP sensor configuration. The PCM also uses the
CKP signal to determine if a misfire has occurred by measuring rapid decelerations between teeth.
Typical CKP Sensor

589
Crankshaft Position Sensor: Service and Repair
Removal
2. Remove the 2 bolts and the accessory drive belt splash shield.
3. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
4. Turn the crankshaft clockwise until the hole in the crankshaft pulley is in the 3 o'clock position.
590
5. NOTE: The cylinder block plug is located on the exhaust side of the engine block near the CKP
sensor.
Remove the cylinder block plug.
6. NOTE: When the crankshaft contacts the Crankshaft TDC Timing Peg, the No. 1 cylinder will be
at Top Dead Center (TDC).
Install the Crankshaft TDC Timing Peg. -
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
7. Remove the CKP sensor retaining bolts and the sensor.
8. NOTICE: Only hand-tighten the bolt or damage to the front cover can occur.
Install a 6 mm x 18 mm standard bolt.
Installation
1. Install the CKP sensor, but do not tighten the 2 bolts at this time.
591
2. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
- Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in).
3. Connect the CKP sensor electrical connector.
4. Remove the 6 mm x 18 mm bolt.
5. Remove the Crankshaft TDC Timing Peg.
6. Install the cylinder block plug.
7. Install the accessory drive belt splash shield and the 2 bolts.

Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page
595
596
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature (CHT) Sensor
Software
Typical CHT Sensor

Operation > Cylinder Head Temperature (CHT) Sensor > Page 599
Sensor


connector.

Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel
Tank and Filler Pipe - Exploded View
Fuel Level Sensor: Service and Repair Fuel Tank and Filler Pipe - Exploded View

Tank and Filler Pipe - Exploded View > Page 605
Fuel Level Sensor: Service and Repair Fuel Pump Module
Fuel Pump Module
personal injury.
ring.
arm.

Fuel Level Sensor: Service and Repair Fuel Level Sender
Fuel Level Sender
personal injury.
1. Remove the Fuel Pump (FP) module. For additional information, refer to Fuel Pump Module
See: Powertrain Management/Fuel Delivery and Air
Induction/Fuel Pump/Service and Repair/Fuel Pump Module.
2. Disconnect the fuel level sender electrical connector.
3. Release the retainer tabs and remove the fuel level sender from the FP module.

Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Fuel Tank Pressure Sensor: Locations
Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
614
Fuel Tank Pressure Sensor: Diagrams
615
616
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure (FTP) Sensor
The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure.
Typical In-tank FTP Sensor
Typical In-line FTP Sensor

Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Intake Air Temperature Sensor: Locations
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
620
Intake Air Temperature Sensor: Diagrams

621
Intake Air Temperature Sensor: Description and Operation
Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor device in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and the resistance increases
as the temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.

total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor
The IAT sensor provides air temperature information to the PCM. The PCM uses the air
temperature information as a correction factor in the calculation of fuel, spark, and air flow.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Currently there are 2 types of IAT sensors used, a stand-alone/non-integrated type and an
integrated type. Both types function the same, however the integrated type is incorporated into the
mass air flow (MAF) sensor instead of being a stand-alone sensor.
Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate
as described above. One is located before the supercharger at the air cleaner for standard
OBD/cold weather input, while a second sensor, intake air temperature 2 (IAT2), is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control spark and to help determine charge air cooler (CAC)
efficiency.
The IAT2 sensor for speed density control systems is centrally located on the intake manifold. The
IAT2 sensor measures the intake manifold temperature. The powertrain control module (PCM)
uses the information from the IAT2 sensor to determine the speed density air charge and provide
input used for various spark control functions. The IAT2 sensor for a speed density system is
integral with the manifold absolute pressure (MAP) sensor.
Typical Stand-Alone/Non-Integrated IAT Snesors

622
Typical Integrated IAT Sensor Integrated Into A Drop-in Or Flange-type MAF Sensor
Typical IAT2 Sensor Integrated With A MAP Sensor

Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 626
Knock Sensor: Diagrams
Knock Sensor: Description and Operation
Knock Sensor (KS)
The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical
signal. The PCM uses this signal to determine the presence of engine knock and to retard spark
timing.
Two Types Of Knock Sensor (KS)

Knock Sensor: Service and Repair
Knock Sensor (KS)
1. Remove the intake manifold. For additional information, refer to Engine.
2. NOTE: The Knock Sensor (KS) must not touch the crankcase vent oil separator.
Remove the bolt and the KS.

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 633
Manifold Pressure/Vacuum Sensor: Diagrams
Page 634
Page 635
Manifold Pressure/Vacuum Sensor: Description and Operation
Manifold Absolute Pressure (MAP) Sensor

The MAP sensor measures intake manifold absolute pressure. The PCM uses information from the
MAP sensor to measure how much exhaust gas is introduced into the intake manifold.
The MAP sensor for speed density control systems is centrally located on the intake manifold. The
MAP sensor measures the intake manifold pressure. The powertrain control module (PCM) uses
the information from the MAP sensor to determine the speed density air charge and provide input
used for various spark control functions. The MAP sensor for a speed density system is integral
with the intake air temperature 2 (IAT2) sensor.
Typical MAP Sensor
Typical MAP Sensor Integrated With An IAT2 Sensor

Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description
and Operation
Oil Temperature Sensor For ECM: Description and Operation

Typical EOT Sensor

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen
Sensor(HO2S) #11
Oxygen Sensor: Locations Heated Oxygen Sensor(HO2S) #11
Sensor(HO2S) #11 > Page 643
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen
Sensor (HO2S) #12
Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) #12

Sensor (HO2S) #12 > Page 646

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation >
Heated Oxygen Sensor (HO2S)
Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S)
The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage
according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in
the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich
air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the
PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during
closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
a temperature of 800°C (1,472°F). At approximately 300°C (572°F) the engine enters closed loop
operation. The VPWR circuit supplies voltage to the heater. The PCM turns the heater on by
providing the ground when the correct conditions occur. The heater allows the engine to enter
closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty
cycled, to prevent damage to the heater.
Typical HO2S
Heated Oxygen Sensor (HO2S) > Page 649
Oxygen Sensor: Description and Operation Universal Heated Oxygen Sensor (HO2S)
Universal Heated Oxygen Sensor (HO2S)
The universal HO2S, sometimes referred to as a wideband oxygen sensor, uses the typical HO2S
combined with a current controller in the PCM to infer an air/fuel ratio relative to the stoichiometric
air/fuel ratio. This is accomplished by balancing the amount of oxygen ions pumped in or out of a
measurement chamber within the sensor. The typical HO2S within the universal HO2S is used to
detect the oxygen content of the exhaust gas in the measurement chamber. The oxygen content
inside the measurement chamber is maintained at the stoichiometric air/fuel ratio by pumping
oxygen ions in and out of the measurement chamber. As the exhaust gasses get richer or leaner,
the amount of oxygen that must be pumped in or out to maintain a stoichiometric air/fuel ratio in the
measurement chamber varies in proportion to the air/fuel ratio. The amount of current required to
pump the oxygen ions in or out of the measurement chamber is used to measure the air/fuel ratio.
The measured air/fuel ratio is actually the output from the current controller in the PCM and not a
signal that comes directly from the sensor.
The universal HO2S also uses a self-contained reference chamber to make sure an oxygen
differential is always present. The oxygen for the reference chamber is supplied by pumping small
amounts of oxygen ions from the measurement chamber into the reference chamber. The universal
HO2S does not need access to outside air.
Part to part variance is compensated for by placing a resistor in the connector. This resistor is used
to trim the current measured by the current controller in the PCM.
Embedded with the sensing element is the universal HO2S heater. The heater allows the engine to
enter closed loop operation sooner. The heating element heats the sensor to a temperature of
780°C (1,436°F). The VPWR circuit supplies voltage to the heater. The PCM controls the heater on
and off by providing the ground to maintain the sensor at the correct temperature for maximum
accuracy.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor -
Exploded View
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 652
Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S)
1. Disconnect the electrical connector and detach the wiring retainer.
2. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in
removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the Heated Oxygen Sensor (HO2S).
- Calculate the correct torque wrench setting for the following torque.
- To install, tighten to 48 Nm (35 lb-ft).
3. NOTICE: Make sure that the sensor wiring is routed away from hot surfaces and sharp edges or
damage to the wiring may occur.
NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S.
NOTE: Make sure that the electrical connector locking tab is engaged.

Oxygen Sensor: Service and Repair Catalyst Monitor Sensor
Catalyst Monitor Sensor
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector and detach the wiring
retainer.
3. Detach the 3 CMS wiring retainers.
removal.
Using the Exhaust Gas Oxygen Sensor Socket, remove the Catalyst Monitor Sensor (CMS).

NOTE: Apply a light coat of anti-seize lubricant to the threads of the CMS.

Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 658
Power Steering Pressure Switch: Diagrams

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

Operation > Power Steering Pressure (PSP) Switch > Page 661
Sensor
Power Steering Pressure (PSP) Sensor
The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP
sensor voltage input to the PCM changes as the hydraulic pressure changes. The PCM uses the
input signal from the PSP sensor to compensate for additional loads on the engine by adjusting the
idle RPM and preventing engine stall during parking maneuvers. Also, the PSP sensor signals the
PCM to adjust the transmission EPC pressure during increased engine load, such as during
parking maneuvers.
Typical PSP Sensor

Power Steering Pressure Switch: Service and Repair
1. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
2. Remove the PSP switch.

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

The tube mounted differential pressure feedback EGR sensor is identical in operation as the larger
plastic differential pressure feedback EGR sensors and uses a 1.0 volt offset. The HI and REF
hose connections are marked on the side of the sensor.
Description and Operation > Page 666

Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Throttle Position Sensor: Description and Operation Electronic Throttle Body Throttle Position
Sensor (ETBTPS)
Electronic Throttle Body Throttle Position Sensor (ETBTPS)
The ETBTPS has 2 signal circuits in the sensor for redundancy. The redundant ETBTPS signals
are required for increased monitoring. The first ETBTPS signal (TPS1-NS) has a negative slope
(increasing angle, decreasing voltage) and the second signal (TPS2-PS) has a positive slope
(increasing angle, increasing voltage). The 2 ETBTPS signals make sure the PCM receives a
correct input even if one signal has a concern. There is 1 reference voltage circuit and 1 signal
return circuit for the sensor that are shared with the reference voltage circuits and signal return
circuits used by the APP sensor. For additional information, refer to Torque Based Electronic
Throttle Control (ETC). See: Powertrain Management/Computers and Control Systems/Electronic
Throttle Control Module/Description and Operation
Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page 671
Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor
Throttle Position (TP) Sensor
The TP sensor is a rotary potentiometer sensor that provides a signal to the PCM that is linearly
proportional to the throttle plate/shaft position. The sensor housing has a 3-blade electrical
connector that may be gold plated. The gold plating increases the corrosion resistance on the
terminals and increases the connector durability. The TP sensor is mounted on the throttle body.
As the TP sensor is rotated by the throttle shaft, 4 operating conditions are determined by the PCM
from the TP. These are: -
closed throttle (includes idle or deceleration)
- part throttle (includes cruise or moderate acceleration)
- wide open throttle (includes maximum acceleration or de-choke on crank)
- throttle angle rate
Typical TP Sensor
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations
Transmission Position Switch/Sensor: Locations
Locations > Page 675
Transmission Position Switch/Sensor: Diagrams
Transmission Position Switch/Sensor: Service and Repair
Transmission Range (TR) Sensor
Removal
1. Disconnect the Transmission Range (TR) sensor electrical connector and the selector lever
cable.
2. NOTE: Failure to hold the manual control lever while loosening or tightening the manual control
lever bolt will transmit rotational torque to the
TR sensor and shift mechanism.

Remove the TR sensor (automatic transaxle shown removed for clarity).
1. Remove the manual control lever.
2. Remove the TR sensor bolts.
Installation
NOTE: Do not fully tighten the bolts at this stage.
Install the TR sensor (automatic transaxle shown removed for clarity).
2. Using the Transmission Range Sensor Alignment Tool, align the TR sensor and tighten the
bolts.
3. NOTICE: Do not use air tools on this bolt. Hold the manual control lever while tightening the
manual control lever bolt, or failure to the
manual control lever shaft or the Transmission Range (TR) sensor could occur.
Install the manual control lever.
- Tighten to 30 Nm (22 lb-ft).
4. NOTICE: Check the manual control lever is in position 3 (D position) or the selector lever cable
will not be adjusted correctly.
Adjust the manual control lever to TR sensor D position.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
- When in position D, the marks on the manual control lever line up with the marks on the TR
sensor.
5. Connect the selector lever cable and the TR sensor electrical connector.
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Output Shaft Speed (OSS) Sensor
Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor
Output Shaft Speed (OSS) Sensor
The OSS sensor provides the PCM with information about the rotational speed of an output shaft.
The PCM uses the information to control and diagnose powertrain behavior. In some applications,
the sensor is also used as the source of vehicle speed. The sensor may be physically located in
different places on the vehicle, depending upon the specific application. The design of each speed
sensor is unique and depends on which powertrain control feature uses the information that is
generated.
> Output Shaft Speed (OSS) Sensor > Page 684
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS)
Vehicle Speed Sensor (VSS)
The VSS is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency
that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low speed, the
sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor
generates a signal with a higher frequency. The PCM uses the frequency signal generated by the
VSS (and other inputs) to control such parameters as fuel injection, ignition control,
transmission/transaxle shift scheduling, and TCC scheduling.
Typical VSS
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description
and Operation

and Operation > Page 689

Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 694

Page 695
2-Track APP Sensor
Electronic Throttle Control (ETC). See: Powertrain Management/Computers and Control
Systems/Electronic Throttle Control Module/Description and Operation
3-Track APP Sensor

Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 699


(TCC) scheduling.
Typical MAF Sensor



Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation > Fuel Rail Pressure (FRP) Sensor
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure (FRP) Sensor
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is a diaphragm strain gauge device. The FRP sensor measures the pressure
difference between the fuel rail and atmospheric pressure. The FRP sensor nominal output varies
between 0.5 and 4.5 volts, with 0.5 volts corresponding to 0 MPa (0 psi) gauge and 4.5 volts
corresponding to 26 MPa (3771 psi) gauge. The sensor can read vacuums and may lower the
output voltage to slightly below 0.5 volts. This condition is normal and is usually the case after
several hours of cold soak before the vehicle dome light is turned on. The fuel pump (FP) module is
energized at the same time the dome light is commanded on. A disabled or malfunctioning dome
light does not affect the FP module control.
The FRP sensor is located on the fuel rail, and provides a feedback signal to indicate the fuel rail
pressure to the PCM. The PCM uses the FRP signal to command the correct injector timing and
pulse width for proper fuel delivery at all speed and load conditions. The FRP sensor, along with
the fuel volume regulator (part of the fuel injection pump), form a closed loop fuel pressure control
system. An electrically faulted FRP sensor results in the deactivation of the fuel injection pump.
Fuel pressure to injectors is then provided only by the FP module. When the fuel injection pump is
de-energized and the injectors are active, the fuel rail pressure is approximately 70 kPa (10 psi)
lower than FP module pressure due to the pressure drop across the fuel injection pump. Thus, if
the FP module pressure is 448 kPa (65 psi), then the fuel rail pressure would be approximately 379
kPa (55 psi) if the injectors are active.

Operation > Fuel Rail Pressure (FRP) Sensor > Page 707
Fuel Pressure Sensor/Switch: Description and Operation Fuel Rail Pressure Temperature (FRPT)
Sensor
Fuel Rail Pressure Temperature (FRPT) Sensor
The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends
these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to
determine the pressure difference between the fuel rail and the intake manifold. The relationship
between fuel pressure and fuel temperature is used to determine the possible presence of fuel
vapor in the fuel rail.
The temperature sensing portion of the FRPT sensor is a thermistor device in which resistance
changes with temperature. The electrical resistance of the thermistor decreases as the temperature
increases, and the resistance increases as the temperature decreases. The varying resistance
changes the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Both the pressure and temperature signals are used to control the speed of the fuel pump. The
speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The
dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the
injector pulse width to decrease.
Typical FRPT Sensor

Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation
Fuel Temperature Sensor: Description and Operation
Typical FRPT Sensor

Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 714
Inertia Fuel Shutoff Switch: Diagrams
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shut-off (IFS) Switch
The IFS switch is used in conjunction with the electric fuel pump. The purpose of the IFS switch is
to shut off the fuel pump if a collision occurs. It consists of an inverted pendulum mass that is
retained in a conical cone via a set of linear springs. When a sharp impact occurs, the pendulum
shifts out of the conical cone, opens the circuit and shuts off the electric fuel pump. Once the switch
is open, it must be manually reset before restarting the vehicle.
Typical IFS Switch

Inertia Fuel Shutoff Switch: Service and Repair
Inertia Fuel Shutoff (IFS) Switch
1. Remove the RF lower cowl trim panel.
2. Disconnect the Inertia Fuel Shutoff (IFS) switch electrical connector.
3. NOTICE: Do not overtighten the fasteners or damage to the switch will occur.
Remove the 2 bolts and the IFS switch.

- If necessary, reset the IFS switch after the installation has been completed.
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
Throttle Control (ETC). See: Powertrain Management/Computers and Control Systems/Electronic
> Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page 722
Typical TP Sensor
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 727


Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 734
Typical CKP Sensor

Removal
sensor.
Installation

Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Removal and Replacement
Ignition Switch Lock Cylinder: Removal and Replacement
Ignition Lock Cylinder
NOTE: For non-functional ignition lock cylinders, the steering column lock module has to be
replaced. For additional information, refer to Steering Column.
1. Remove the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to
Antitheft and Alarm Systems.
2. Remove the ignition lock cylinder.
1. Insert and turn the ignition key to the ACC (I) position.
2. Using a suitable tool such as a pick, press the detent.
3. Remove the lock cylinder.
3. If a new lock cylinder with keys is replaced, the new PATS keys must be programmed. For
additional information, refer to Key Programming
Using Diagnostic Equipment in Antitheft and Alarm Systems. See: Accessories and Optional
Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and Relearning/Key
Programming Using Diagnostic Equipment

> Removal and Replacement > Page 745
Ignition Switch Lock Cylinder: Overhaul
Assembly
NOTE: This lock cylinder cannot be disassembled. This procedure is for assembly only.
1. NOTE: The tumblers required can be determined from the vehicle keycode. If necessary, the
factory keycode can be obtained from authorized
dealership personnel.
Select the required tumblers according to the key cut depths for each position from A through F.
2. NOTE: Make sure that the tumbler and spacer indents align with the locking pin slot.
Install the ignition lock cylinder tumblers and spacers into the ignition lock cylinder barrel as follows:
3. Using a suitable tool (such as a center punch or chisel), crimp the ignition lock cylinder barrel to
secure the tumbler retainer.
4. Apply the multi-purpose grease on the lock cylinder barrel in and around the locking pin slot and
in the tumbler retainer.
5. NOTE: Install the key hole shield so that the wider land is covering the keyhole.
Install the ignition lock cylinder key hole shield

6. Place the locking pin into the locking pin slot.
7. Slide the ignition lock cylinder body onto the ignition lock cylinder barrel.
8. Install the ignition lock cylinder barrel retaining clip.
9. Install the ignition lock cylinder security clip noting its correct position.
10. Spray a small amount of the multi-purpose grease into the key hole.
Switches - Ignition System > Knock Sensor > Component Information > Locations
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 751
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Air Bag Deactivation Switch: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Front Impact Sensor, Left
Impact Sensor: Locations Front Impact Sensor, Left
Component Information > Locations > Front Impact Sensor, Left > Page 763
Impact Sensor: Locations Front Impact Sensor, Right
Impact Sensor: Locations Side Impact Sensor, Driver
Impact Sensor: Locations Side Impact Sensor, Passenger
Component Information > Diagrams > Front Impact Sensor, Left
Impact Sensor: Diagrams Front Impact Sensor, Left

Component Information > Diagrams > Front Impact Sensor, Left > Page 768
Impact Sensor: Diagrams Front Impact Sensor, Right

Impact Sensor: Diagrams Side Impact Sensor, Driver

Impact Sensor: Diagrams Side Impact Sensor, Passenger

Component Information > Service and Repair > Front Impact Severity Sensor
Impact Sensor: Service and Repair Front Impact Severity Sensor
Front Impact Severity Sensor
NOTE: LH shown, RH similar.

2. Remove the 2 bolts and front impact severity sensor and bracket.
3. Disconnect the front impact severity sensor electrical connector.
4. Secure the front impact severity sensor bracket in a holding device.
Remove the nut and front impact severity sensor from the bracket. -
To install, tighten to 9 Nm (80 lb-in).

Component Information > Service and Repair > Front Impact Severity Sensor > Page 773
7. Repower the SRS. For additional information, refer to Supplemental Restraint System (SRS)

Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering.
Impact Sensor: Service and Repair Side Impact Sensor
Side Impact Sensor
NOTE: RH shown, LH similar.

2. Remove the B-pillar trim panels.
3. Remove the side impact sensor.
- Remove the nut. -
- Remove the sensor from the stud.
- Disconnect the impact sensor.

Disarming/Service and Repair/Supplemental Restraint
System (SRS) Depowering and Repowering in the General Procedures.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >
Seat Occupant Sensor: Locations
Seat Occupant Sensor: Diagrams

Seat Occupant Sensor: Service and Repair
Occupant Classification Sensor
Service Kit Occupant Classification Sensor (OCS) System
Removal
NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification Sensor
(OCS) system reset when a front passenger seat cushion is disassembled, a new cover installed or
an OCS system service kit is installed. A scan tool is used to carry out the OCS system reset.
NOTE: An OCS system service kit has the electrical connector glued to the Occupant Classification
System Module (OCSM). It cannot and should not be disconnected or altered.
1. Remove the passenger seat. For additional information, refer to the Removal and Installation
portion of Seats.
2. Remove the screw, slide up and remove the recliner handle.
3. If equipped, remove the height adjust handle.
- Release the locking tab behind the handle.
4. Remove the screw and outboard side shield.
- Release at the rear, slide and rotate forward to remove.
5. Remove the screw and inboard side shield.
- Detach the safety belt buckle wire harness.
6. Release all backrest cover strap clips from under the seat.
7. Release all J-clips and invert the cushion cover.
8. Remove all hog rings and cushion cover.
9. Detach the seat electrical bulkhead connector and wire harness from the seat track.
10. Insert a suitable tool to release the locking tabs and remove the brown safety belt buckle
electrical connector and yellow side air bag connector
from the seat electrical bulkhead connector.
11. Release the 2 pin-type retainers and separate the OCS bladder from the cushion half pan.
12. Release the clip and detach the pressure sensor hose from the suspension spring.
13. Insert a suitable tool between the pressure sensor and bracket to release the locking tab and
remove the pressure sensor from the cushion half pan
bracket.
14. Remove the 2 screws and detach the OCSM from the cushion half pan.
15. Remove the OCS system components and seat wiring through the opening in the suspension
spring.
Installation
WARNING: Make sure the front passenger seat repair is complete, the seat and all attached
components (head restraint, seat side shield, etc.) are correctly assembled, and the seat is
correctly installed to the vehicle before carrying out the System Reset. Failure to follow these
instructions may result in incorrect operation of the occupant classification sensor (OCS) system
and increases the risk of serious personal injury or death in a crash.
1. WARNING: Install a new occupant classification sensor (OCS) system service kit as a complete
assembly. Never install only part of the
kit components. Failure to follow this instruction may result in incorrect operation of the OCS
system and increases the risk of serious personal injury or death in a crash.
Install the OCS bladder and foam. -
Route the OCS system components and seat wiring through the opening in the suspension spring.
- Position the OCS bladder to the cushion half pan and install the 2 pin-type retainers.
2. Bend the locking tab back on the pressure sensor bracket and install the pressure sensor onto
the bracket making sure the locking tab is completely
engaged. -
Check the pressure sensor bracket mounting for tightness. If the bracket is loose, install a new rivet
to tighten the bracket.
3. Attach the 2 pin-type retainers and OCS bladder to the cushion half pan.
4. Attach the pressure sensor hose clip to the suspension spring.
5. Install the OCSM and 2 screws.
6. Install the brown safety belt buckle electrical connector and yellow side air bag connector to the
seat electrical bulkhead connector.
7. Install the wire harness.
- Install the wire harness and retainers to the seat track.
- Attach the seat electrical bulkhead connector to the seat track.
8. Install the cushion cover and all hog rings to the foam pad.
9. Fasten all cushion cover J-clips.
10. Install the inboard side shield and screw.
- Attach the safety belt buckle wire harness.
11. Install the outboard side shield and screw.
12. If equipped, install the height adjust handle.
13. Install the recliner handle and screw.
14. Install the passenger seat. For additional information, refer to the Removal and Installation
portion of Seats.
15. NOTICE: To prevent system failure, it is necessary to carry out the Occupant Classification
Sensor (OCS) system reset when a front
passenger seat cushion is disassembled, a new trim cover is installed or an OCS system service
kit is installed. A scan tool is used to carry out the OCS system reset.
Make sure no Occupant Classification System Module (OCSM) DTCs are present. If DTC C1941
has been stored in OCSM memory it will clear upon a successful system reset. All other OCS
system DTCs must be diagnosed and repaired before carrying out the OCS system reset.
16. WARNING: Make sure the front passenger seat repair is complete, the seat and all attached
components (head restraint, seat side shield,
etc.) are correctly assembled, and the seat is correctly installed to the vehicle before carrying out
the System Reset. Failure to follow these instructions may result in incorrect operation of the
occupant classification sensor (OCS) system and increases the risk of serious personal injury or
death in a crash.
NOTICE: To prevent system failure, the following precautions must be taken before carrying out
the Occupant Classification Sensor (OCS) system reset: -
Make sure the voltage to the Occupant Classification System Module (OCSM) is above 8 volts and
less than 18 volts.
- Make sure the OCS system is not at a temperature below 6°C (42°F) or above 36°C (97°F) when
initiating the OCS system reset. If the vehicle has been exposed to extreme cold or hot
temperatures, the vehicle must be exposed and kept at a temperature within the limits, 6°C to 36°C
(42°F to 97°F) for a minimum of 30 minutes.
- Make sure nothing is present on the passenger seat before carrying out the OCS system reset
and nothing is placed on the seat during the process.
- Make sure a minimum 8-second time period has passed after cycling the ignition ON before
carrying out the OCS system reset.
Carry out the Occupant Classification Sensor (OCS) system reset.
17. If the first system reset attempt was unsuccessful, carry out a thorough inspection of the
following and repair any concerns found.
- OCS system connector and wiring for damage
- Pressure sensor hose for kinks and/or damage
- Seat-related wiring harness and body wiring harness terminals and connectors for damage
18. Carry out a second OCS system reset. If unsuccessful, install a new OCS system service kit.
19. Prove out the Supplemental Restraint System (SRS) as follows:
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition ON and monitor the air
bag warning indicator with the air bag modules installed. The air bag warning indicator will light
continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is detected, the
air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not
occur until approximately 30 seconds after the ignition has been turned from the OFF to the ON
position. This is the time required to complete testing of the SRS. If the air bag warning indicator is
inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this
occurs, the air bag warning indicator and any SRS fault discovered must be diagnosed and
repaired. Clear all RCM and OCSM CMDTCs.
20. NOTE: A prepaid return postcard is provided with a new OCS system service kit. The serial
number for the new part and the Vehicle
Identification Number (VIN) must be recorded and sent to Ford Motor Company.
If a new OCS system service kit was installed, fill out the necessary information on the OCS
system traceability card and return it along with the complete inoperative OCS system to Ford
Motor Company. -
When returning the inoperative OCS system, include: foam pad, bladder, OCSM, pressure sensor,
hose, electrical connectors and wire harness (OCS system service kit OCS only).
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Seat Position Sensor: Locations
Seat Position Sensor: Diagrams

Seat Position Sensor: Service and Repair
Seat Position Sensor
1. Remove the driver seat. For additional information, refer to Seats.
2. Disconnect the seat position sensor electrical connector.
3. Compress the tab and remove the seat position sensor from the seat bracket slots.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal and Replacement

Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal and Replacement > Page 798
Assembly

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
Neutral Safety Switch: Locations
Neutral Safety Switch: Diagrams
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 811

Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Power
Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

Steering Pressure (PSP) Switch > Page 814
Sensor
parking maneuvers.
Typical PSP Sensor

Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Page 815

Switches - Steering > Steering Angle Sensor > Component Information > Locations
Steering Angle Sensor: Locations
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 819
Steering Angle Sensor: Diagrams

Switches - Suspension > Steering Angle Sensor > Component Information > Locations
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 824

Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure
Monitoring System (TPMS) Sensor Training
Tire Pressure Sensor: Testing and Inspection Tire Pressure Monitoring System (TPMS) Sensor
Training
Tire Pressure Monitoring System (TPMS) Sensor Training
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the
latest tire pressure information to the Tire Pressure Monitoring System (TPMS). For additional
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Instrument
Panel, Gauges and Warning Indicators/Tire Monitoring System/Testing and
Inspection/Programming and Relearning.
NOTE: The TPMS Sensor Training procedure must be done on a single vehicle, in an area without
Radio Frequency Interference (RFI) and at least 1 m (3 ft) away from other vehicles equipped with
TPMS. RFI is generated by certain electrical motors and appliance operation, cellular telephone
chargers, remote transmitters, power inverters and portable entertainment equipment.
NOTE: The TPMS/Vehicle Security Module (VSM) has a 2-minute time limit between sensor
responses. If the TPMS/VSM does not recognize any 1 of the 4 tire pressure sensors during this
time limit, the horn will sound twice and the entire procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures the tire pressure sensors must be
trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to
illuminate.
1. Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
- The horn will sound once and the TPMS indicator will flash if the training mode has been entered
successfully.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in
place at the valve stem.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle
to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If
the sensor still does not respond, attempt to activate the same sensor again using the customer
activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the
vehicle doors open.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and
release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to
indicate that the tire pressure sensor has been recognized by the TPMS/VSM.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall at the valve stem and press and
release the test button to train the RF tire pressure sensor.

Monitoring System (TPMS) Sensor Training > Page 830
8. NOTE: Do not wait more than 2 minutes between training each sensor or the TPMS/VSM will
time out and the entire procedure must be
repeated.
Repeat Step 7 for the RR and LR tires. The procedure is completed after the last tire has been
trained. Successful completion of the training procedure will be verified by turning the ignition
switch to the OFF position without the horn sounding. If the horn sounds twice when the switch is
turned to the OFF position, the training procedure was not successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the TPMS/VSM and
document them on the applicable warranty claim.
10. NOTE: This step is required to clear DTC C2780, cause the TPMS/VSM to exit the
manufacturing mode and to make sure there are no other
concerns with a newly programmed TPMS/VSM.
If the sensors are being trained due to the installation of a new TPMS/VSM, clear any DTCs and
carry out the TPMS/VSM On-Demand Self Test.
Activation
Tire Pressure Monitoring System (TPMS) Sensor Activation
NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to
conserve battery power. The sensors do not transmit information while in sleep mode. It will be
necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position.
2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve
stem.
3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing
green light and a beep sound for each
successful response from a tire pressure sensor. This feedback may not always be present, do not
rely on it as a confirmation that the module heard a particular sensor.
vehicle doors open.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate
the sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and
activating each sensor, refer to the Symptom
Chart in Diagnosis and Testing. See: Instrument Panel, Gauges and Warning Indicators/Tire
Monitoring System/Testing and Inspection/Symptom Related Diagnostic Procedures
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position (BPP)
Switch
Brake Switch - TCC: Description and Operation Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position (BPP)
Switch > Page 838
Brake Switch - TCC: Description and Operation Brake Pressure Switch
strategy.
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
Transmission Control Switch (TCS)
The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature,
the TCIL illuminates when the TCS is cycled to disengage overdrive.
Typical Stalk Mounted TCS
Typical Shift Selector Lever Mounted TCS

Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 845
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor
Transmission Speed Sensor: Locations Output Shaft Speed (OSS) Sensor
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor > Page 854
Transmission Speed Sensor: Locations Turbine Shaft Speed (TSS) Sensor
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS)
Sensor
Transmission Speed Sensor: Diagrams Output Shaft Speed (OSS) Sensor

Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS)
Sensor > Page 857
Transmission Speed Sensor: Diagrams Turbine Shaft Speed (TSS) Sensor

Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed
(TSS) Sensor
Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor
Turbine Shaft Speed (TSS) Sensor
Removal
1. Remove the battery tray. For additional information, refer to Battery.
2. Remove the Air Cleaner (ACL) assembly. For additional information, refer to Fuel Delivery and
Air Induction.
3. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.

(TSS) Sensor > Page 860
4. Remove the TSS sensor bolt and sensor.
- Check the TSS sensor bore.
5. Inspect the O-ring seal for nicks or cuts; install a new O-ring if necessary.
Installation
1. Apply a light coat of clean transmission fluid to the O-ring seal before installation.
2. NOTE: Apply thread sealer to the bolt.
Install the TSS sensor and bolt.
3. Connect the TSS sensor electrical connector.
4. Install the ACL assembly. For additional information, refer to Fuel Delivery and Air Induction.
5. Install the battery tray. For additional information, refer to Battery.

Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor
Removal
2. Place a drain pan beneath the Output Shaft Speed (OSS) sensor.
3. Remove the OSS sensor.
- Remove the bolt.
- Inspect the OSS bore.
Installation
1. NOTE: Apply a light coat of clean transmission fluid to the O-ring before installation.
Install the OSS sensor.
- Connect the electrical connector.
2. Lower vehicle.
3. Check the transmission fluid level and add transmission fluid as necessary.
4. Start the engine and move the transaxle range selector lever through all gear positions.
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Heated Glass Element Switch: Locations
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Heated Glass Element Switch: Diagrams

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Power Window Switch: Locations
Power Window Switch: Diagrams
Power Window Switch: Testing and Inspection
Power Window Switch: Service and Repair
Window Control Switch
1. Remove the rear section of the floor console. For additional information, refer to Console - Floor
in Instrument Cluster / Carrier &/or Interior
Moulding / Trim.
2. The power window control switch(es) are each locked into the switch bezel with 4 small tabs. To
remove the switch(es), unlock the tabs and pull
the switch toward the inside of the console.

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
Windshield Washer Switch: Locations
Washer Switch > Component Information > Locations > Page 882
Windshield Washer Switch: Diagrams
Windshield Washer Switch: Testing and Inspection
Windshield Washer Switch: Service and Repair
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Wiper/Washer Switch
Wiper Switch: Locations Wiper/Washer Switch
Component Information > Locations > Wiper/Washer Switch > Page 892
Wiper Switch: Locations Multifunction Switch
Component Information > Diagrams > Multifunction Switch
Wiper Switch: Diagrams Multifunction Switch
Component Information > Diagrams > Multifunction Switch > Page 895
Wiper Switch: Diagrams Wiper/Washer Switch
Component Information > Testing and Inspection > Wiper/Washer Switch
Wiper Switch: Testing and Inspection Wiper/Washer Switch
Component Information > Testing and Inspection > Wiper/Washer Switch > Page 900
Wiper Switch: Testing and Inspection Multifunction Switch
Component Information > Testing and Inspection > Page 903
Wiper Switch: Service and Repair
All vehicles
Steering Column.

Component Information > Testing and Inspection > Page 904
All vehicles

Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Alignment: Specifications Alignment Specifications
Alignment Specifications (at curb weight)

Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 910
Alignment: Specifications General Specifications
General Specifications
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Alignment Specifications >
Page 911
Alignment: Specifications Torque Specifications
Torque Specifications
a Refer to the procedure.

Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 912
Alignment: Description and Operation
Wheel Alignment Angles
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut
and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the
best directional stability characteristics when loaded and driven. The caster setting is not related to
tire wear. The caster setting is not adjustable.
A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a
separate procedure on this vehicle. Front caster should fall within specification when the front
camber is adjusted.
Toe
Positive Toe (Toe In)
Negative Toe (Toe Out)

The vehicle toe setting affects tire wear and directional stability.
Incorrect Thrust Angle (Dogtracking)
Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not
square to the chassis. Heavily crowned roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering
wheel resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and experienced by the driver as small rotational oscillations of the steering wheel.
For wheel and tire diagnosis, refer to Wheels and Tires.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering are used to describe the poor return of the steering wheel to
center after a turn or steering correction.
Drift/Pull
Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
- A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead
path and requires constant steering input in the opposite direction to counteract the effect.
- Drift/pull may be induced by conditions external to the vehicle (wind or road crown).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Effort may be said to be "flat on-center."
- Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the
gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
- In the diagnosis of a driveability problem, it is important to understand the difference between

wander and poor groove feel.
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment - Front
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment - Front
Camber Adjustment
1. Using alignment equipment and the manufacturer's instructions, measure the camber settings.
2. NOTE: By loosening the strut rod nut and either pushing the strut inboard or pulling it outboard
the camber can be adjusted by approximately
0.25 degree.
Loosen the strut rod nut.

- To make a negative camber adjustment, loosen the strut rod nut and push the strut inboard.
- To make a positive camber adjustment, loosen the strut rod nut and pull the strut outboard.
- Tighten the nut to 59 Nm (44 lb-ft).
3. NOTICE: The wheel knuckle-to-strut bolt is tightened in 2 stages. Failure to follow these
instructions may result in incorrect clamp load
and component damage.
To make a positive camber adjustment, loosen the wheel knuckle-to-strut bolt with the vehicle
supported by the subframe. This will allow the strut to sit on the wheel knuckle-to-strut bolt.
- Stage 1: Tighten the bolt to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
To make a negative camber adjustment, loosen the wheel knuckle-to-strut bolt with the weight of
the vehicle on the wheel and tire. This will allow the struts weight to fully lift up on the wheel
knuckle-to-strut bolt.

Adjustment - Front > Page 917
5. Check and if necessary, adjust the front toe. For additional information, refer to Toe Adjustment -
Front See: Toe Adjustment - Front.
6. If equipped with Advance Track(R) and Roll Stability Control (RSC(R)), calibrate the ABS
module.
directions.
Cross Camber Adjustment
2. Loosen the 4 subframe rearward bolts and the 2 subframe forward bolts approximately 2 or 3
turns (720-1080 degrees of rotation).
3. NOTE: Shifting the subframe towards the passenger side will increase the driver side camber
and decrease the passengers side camber. Shifting
the subframe towards the driver side will increase the passenger side camber and decrease the
drivers side camber.
Shift the subframe to change the cross camber as required.
4. NOTE: Tightening the subframe bolts in the correct sequence will minimize subframe shifting.
Tighten the 6 subframe bolts in the following sequence.
1. Tighten the 2 rearward outboard bolts to 200 Nm (148 lb-ft).
2. Tighten the 2 forward bolts to 125 Nm (92 lb-ft).
3. Tighten the 2 rearward inboard bolts to 200 Nm (148 lb-ft).
module.
directions.
Cross Caster Adjustment
1. Using alignment equipment and the manufacturer's instructions, measure the caster settings.
3. NOTE: Shifting the subframe forward will increase the caster. Shifting the subframe rearward will
decrease the caster.
Shift the subframe to change the cross caster as needed.
module.
directions.
Alignment: Service and Repair Toe Adjustment - Front
Toe Adjustment - Front
1. Using a suitable steering wheel holding device, lock the steering wheel in the straight ahead
position.
2. Using alignment equipment and the manufacturer's instructions, measure the toe.
3. Loosen the tie-rod jam nuts.
4. Remove the steering gear boot outer clamps.
5. Rotate the tie rods as necessary to adjust the toe setting.
6. Tighten the tie-rod jam nuts to 80 Nm (59 lb-ft).
7. Install the steering gear boot outer clamps.
8. Recheck the toe settings, adjust as necessary.
module.
directions.
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
Fuel Pressure
Key ON Engine OFF (KOEO) and Key ON Engine Running (KOER) fuel
pressure........................................................................393-413 kPa (57-60 psi)
> Specifications > Page 924
Fuel Pressure: Testing and Inspection
Fuel System Pressure Test
personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service
and Repair.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Insert the Spring Lock Coupling Disconnect Tool into the spring lock coupling and release the
fuel jumper tube from the fuel rail.
4. Install the Fuel Pressure Test Kit between the fuel jumper tube and the fuel rail.
5. NOTE: The Inertia Fuel Shutoff (IFS) switch was previously disconnected in the fuel system
pressure release.
Connect the IFS switch electrical connector.
6. Connect the battery ground cable. For additional information, refer to Battery.
7. NOTE: Carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks prior to
completing the Fuel System Pressure Test.
NOTE: After completion of the fuel system pressure test, open the drain valve on the Fuel Pressure
Test Kit and release any residual fuel into a suitable container prior to removing.
Test the fuel system pressure to make sure it is within the specified range. For additional
information, refer to Specifications.
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Diagrams
Air Filter Element: Diagrams
Intake Air System Components - Exploded View

Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
Fuel System Pressure Release
3. Start the engine and allow it to idle until it stalls.
4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel
system pressure has been released.
6. When fuel system service is complete, reconnect the IFS switch electrical connector.
7. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
8. Start the vehicle and check the fuel system for leaks.
9. Install the RF lower cowl trim panel.

Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Firing Order..........................................................................................................................................
.........................................................................1-3-4-2
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Gap
Spark Plug: Specifications Gap
Spark Plug Gap....................................................................................................................................

....................................1.25-1.35 mm (0.049-0.053 in)
Information > Specifications > Gap > Page 941
Spark Plug: Specifications Torque Specifications
Spark Plugs..........................................................................................................................................
........................................................12 Nm 106 (lb-in)
Information > Specifications > Page 942
Spark Plug: Application and ID
Spark Plug............................................................................................................................................
...............................................................AGSF32YPC
Spark Plug: Testing and Inspection
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.
- Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or
carbon fouling.
- Install a new spark plug.
2. Check for oil fouling.
- Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
- Correct the oil leak concern.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips,
exposed shell surfaces and electrodes, caused by a
spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling.
-
Install new spark plugs.
4. Inspect for normal burning.
- Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine
damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized
installation of a heli-coil insert in place of the spark plug threads. -
Install a new spark plug.

6. Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of
electrodes. This is caused by engine overheating,
wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump
pressure or incorrect ignition timing. -

7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
- Install new spark plugs.

Information > Service and Repair > Engine Ignition Components - Exploded View
Spark Plug: Service and Repair Engine Ignition Components - Exploded View
Engine Ignition Components - Exploded View

Information > Service and Repair > Engine Ignition Components - Exploded View > Page 947
Spark Plug: Service and Repair Spark Plugs
Spark Plugs
1. Remove the ignition coil-on-plugs. For additional information, refer to Ignition Coil-On-Plug See:
Powertrain Management/Ignition
System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug.
2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage can occur
to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug wells prior to removing
the spark plugs.
Remove the spark plugs.
3. Inspect the spark plugs. For additional information, refer to Engine.
- Adjust the spark plug gap as necessary.

Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Specifications
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
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford
specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure
check on these cylinders.
Compression Test - Interpreting Compression Readings
1. If compression improves considerably, piston rings are worn or damaged.
2. If compression does not improve, valves are sticking or not seating correctly.
3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does
not increase compression, the head gasket may be
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75% of the highest reading.
Information > System Diagnosis > Compression Test
Compression Check: Testing and Inspection Compression Test
Engine
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.

Information > System Diagnosis > Compression Test > Page 953
leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
Information > System Diagnosis > Compression Test > Page 954
Compression Check: Testing and Inspection Cylinder Leakage Detection
Engine
Cylinder Leakage Detection
When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in
pinpointing the exact cause.
The leakage tester is inserted in the spark plug hole, the piston is brought up to Top Dead Center
(TDC) on the compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of
leakage. Leakage exceeding 20% is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the
intake valve will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the
tailpipe. Leakage past the piston rings will be audible at the PCV connection. If air is passing
through a blown head gasket to an adjacent cylinder, the noise will be evident at the spark plug
hole of the cylinder into which the air is leaking. Cracks in the cylinder block or gasket leakage into
the cooling system may be detected by a stream of bubbles in the radiator.
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Adjustments
Valve Clearance: Adjustments
Valve Clearance Check
1. Remove the valve cover. For additional information, refer to Valve Cover See: Engine, Cooling
and Exhaust/Engine/Service and Repair/Removal
and Replacement/Valve Cover.
2. Remove the 2 bolts and accessory drive belt splash shield.
3. NOTE: Turn the engine clockwise only, and use the crankshaft bolt only.
NOTE: Measure each valve's clearance at base circle, with the lobe pointed away from the tappet,
before removing the camshafts. Failure to measure all clearances prior to removing the camshafts
will necessitate repeated removal and installation and wasted labor time.
Use a feeler gauge to measure each valve's clearance and record its location.
4. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For
example, a tappet with the number 0.650 has the
thickness of 3.650 mm.
NOTE: The nominal desired mid-range clearance is: -
intake: 0.25 mm (0.0095 in).
- exhaust: 0.30 mm (0.0115 in).
Select tappets using this formula: tappet thickness = measured clearance + the existing tappet
thickness - nominal clearance.
NOTE: The acceptable clearances after being fully installed are: -
intake: 0.22-0.28 mm (0.008-0.011 in).
- exhaust: 0.27-0.33 mm (0.010-0.013 in).
Select the closest tappet size to the ideal tappet thickness available and mark the installation
location.
5. If any tappets do not measure within specifications, install new tappets in these locations. For
additional information, refer to Valve Train
Components - Exploded View See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and
Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components -
Exploded View and Valve Tappets See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and
Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets.
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory
Drive (FEAD) - Exploded View
Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View
Front End Accessory Drive (FEAD) - Exploded View

Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Front End Accessory
Drive (FEAD) - Exploded View > Page 962
Drive Belt: Service and Repair Accessory Drive Belt
Accessory Drive Belt
3. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the
accessory drive belt.

Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Diagrams

Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair

Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Diagrams
Oil Filter: Diagrams
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
Compressor To Condenser Discharge Line
Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line
Compressor to Condenser Discharge Line

Compressor To Condenser Discharge Line > Page 980
2. Recover the refrigerant.

3. Remove the high-pressure service gauge port valve extension bracket nut.
4. Remove the 4 lower radiator air deflector pin-type retainers and the lower radiator air deflector.
5. Remove the 3 RH lower splash shield screws, the RH lower splash shield pin-type retainer and
the RH lower splash shield.
6. Remove the 2 LH lower splash shield screws, the LH lower splash shield pin-type retainer and
the LH lower splash shield.
7. Remove the condenser-to-evaporator line bracket nut at the lower radiator support.
- Discard the O-ring seal and gasket seal.
8. NOTICE: To prevent damage to the cooling module, place several shop towels or similar
between the jackstand and cooling module
before resting the cooling module on the jackstand.
Position a suitable jackstand below the lower radiator support to support the cooling module.
9. NOTE: The cooling module will have to be held in position and the jackstand will have to be
lowered to remove the lower radiator support. The
cooling module must then be positioned back onto the jackstand.
Remove the 4 lower radiator support bolts and the lower radiator support.

10. Remove the compressor-to-condenser discharge line bracket nut.
11. Remove the A/C compressor suction fitting nut and disconnect the fitting.
12. Remove the A/C compressor discharge fitting nut and disconnect the fitting.
13. Remove the condenser inlet fitting nut and disconnect the fitting.
- Discard the O-ring seal.
14. Remove the compressor-to-condenser discharge line.
- Install new gasket seals and O-ring seals.
- Add the correct amount of clean PAG oil to the refrigerant system.
16. Evacuate, leak test and charge the refrigerant system.

Hose/Line HVAC: Service and Repair Condenser To Evaporator Line
Condenser to Evaporator Line

ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Hose/Line HVAC: Service and Repair Evaporator Outlet Line

Evaporator Outlet Line
3. Disconnect the evaporator outlet fitting.
- Discard the O-ring seals.
4. Disconnect the A/C cycling switch electrical connector.
5. Remove the RH fender splash shield.
6. Disconnect the suction accumulator inlet fitting.
7. Detach the evaporator outlet line from the 2 line routing clips.
8. Remove the evaporator outlet line.


Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Steering Gear To Fluid Cooler Return Hose
Power Steering Line/Hose: Service and Repair Steering Gear To Fluid Cooler Return Hose
Steering Gear to Fluid Cooler Return Hose
NOTICE: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power
Repair > Steering Gear To Fluid Cooler Return Hose > Page 990
steering components may result.
NOTICE: Do not allow power steering fluid to contact the accessory drive belt or damage to the belt
may occur.
1. Remove the battery and battery tray. For additional information, refer to Battery.
2. Detach the return hose from the 2 pressure and return line retainers.
3. Using the Spring Lock Coupling Disconnect Tool, separate the return hose from the cooler line.
4. Remove the steering line-to-steering gear retainer bolt.
5. Disconnect the pressure line from the steering gear.
- Remove the steering line clamp plate bolt and rotate the clamp plate. -
Discard the O-ring seal.
6. Disconnect the return hose from the steering gear.
7. Detach the 2 oil pressure sending unit harness clips from the return hose.
9. Disconnect the selector lever cable from the transmission.
- Pinch the selector lever cable retainer clips together and carefully pull outward to detach the cable
from the cable bracket.
- Carefully pull outward on the cable end to detach it from the shift shaft lever.
- Position the cable and retainer away from the pressure line.
10. Remove the return hose.
11. NOTE: Make sure the return hose is routed correctly.
- Install 2 new O-ring seals.
12. Fill the power steering system. For additional information, refer to Steering.
Power Steering Line/Hose: Service and Repair Power Steering Pump To Steering Gear Pressure
Line
Power Steering Pump to Steering Gear Pressure Line

foreign material or failure of the power steering components may result.
may occur.
2. Detach the pressure line from the 2 pressure and return line retainers.
3. Remove the power steering pump pulley. For additional information, refer to Power Steering
Pump Pulley See: Steering and
Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering

Pump Pulley.
4. Disconnect the Power Steering Pressure (PSP) sensor electrical connector.
5. Remove the PSP sensor from the pressure line.

6. Disconnect the pressure line fitting from the power steering pump.
7. Remove the pressure line bracket from the A/C compressor stud.
- Detach the wiring harness pin-type retainer from the bracket.
- Remove the pressure line-to-A/C compressor stud nut. -
8. Detach the oil pressure sending unit wiring harness retainer from the pressure line
bracket-to-starter stud.
9. Remove the nut from the pressure line bracket-to-starter stud and position the pressure line
bracket aside.

14. Remove the pressure line.
15. Remove and discard the Teflon(R) seal from the pressure line fitting.
16. NOTE: Make sure the pressure line is routed correctly.

- Using the Teflon(R) Seal Installer Set, install a new Teflon(R) seal on the pressure line fitting.
- Install a new O-ring seal.
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Ford Part Name - Motorcraft High Performance DOT 4 Motor Vehicle Brake Fluid
Ford Part Number - YS4Z-19542-AA
Ford Specification - ESD-M6C57-A or WSS-M6C57-A2

Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity:
..............................................................................................................................................................
..................................................... 6.1 qts (5.7 Liters)
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1002
Coolant: Fluid Type Specifications
Engine Coolant
Ford Part Name - Motorcraft Specialty Orange Engine Coolant with bittering agent
Ford Part Number - VC-3-B (US) - CVC-3-B (Canada)
Ford Specification - WSS-M97B44-D
NOTE: Add the coolant type originally equipped in your vehicle.

Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Automatic Transmission Fluid
Capacity ...............................................................................................................................................
................................................. 7.1 quarts (6.7 liters) NOTE: Approximate dry-fill capacity including
transmission fluid cooling system, actual refill capacities will vary based on vehicle and
transmission fluid cooling system (i.e. coolers size, cooling lines, auxiliary cooler capacity). The
amount of transmission fluid and fluid level should be set by the indication on the dipstick's normal
range.
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Fluid - A/T: Fluid Type Specifications
Ford Part Name - Motorcraft MERCON LV ATF
Ford Part Number - XT-10-QLV
Ford Specification - MERCON LV
NOTE: Automatic transmissions that require MERCON LV should only use MERCON LV fluid. Use
of any fluid other then the recommended fluid may cause transmission damage.
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair >
Transmission Fluid Exchange
Fluid - A/T: Service and Repair Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 49°C-60°C (120°F-140°
F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is
needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
Transmission Fluid Exchange > Page 1010
Fluid - A/T: Service and Repair 4F27E
Transmission Fluid Cooler Backflushing and Cleaning
NOTICE: The use of any transmission fluid other than what is recommended for this transaxle will
cause transaxle damage. Refer to the fluid specification for the correct fluid.
NOTICE: Do not use water-based cleaners, mineral spirits, brake cleaner or solvents that may
contain acetone, xylene or heptane to clean and/or flush the transaxle assembly, transaxle
components or the torque converter, transaxle damage will occur. Use only clean transmission fluid
designated for this transmission.
1. Carry out backflushing with a 7AR Transmission Heated Cooler Line and Flusher. Test
equipment to make sure that a vigorous transmission fluid
flow is present before proceeding. Install a new system filter if flow is weak or contaminated.
2. Remove the transmission fluid cooler tubes. For additional information, refer to Transmission
Cooler, A/T.
3. To aid in attaching the 7AR Transmission Heated Cooler Line and Flusher to the transmission
fluid cooler, install rubber hoses on the metal inlet
and outlet tubes on the transmission fluid cooler. Install the 7AR Transmission Heated Cooler Line
and Flusher on the rubber hoses as follows:
1. Connect the 7AR Transmission Heated Cooler Line and Flusher tank pressure tube to the
transmission fluid cooler return tube.
2. Connect a tank return hose to the transmission fluid cooler pressure tube. Place the outlet end of
this hose in the transmission fluid tank
reservoir.
4. Turn on the transmission fluid pump and allow the transmission fluid to circulate a minimum of 5
minutes (cycling switch on and off will help
dislodge contaminants in cooling system).
5. Switch off the 7AR Transmission Heated Cooler Line and Flusher and disconnect the pressure
hose from the transmission fluid cooler return tube.
6. Clean the transmission fluid cooler tubes by hand.
7. Use compressed air to blow out the cooler(s) and tubes (blow air into the transmission fluid
cooler return tube) until all fluid is removed.
8. Remove the rubber hoses from the transmission fluid cooler and install the transmission fluid
cooler tubes. For additional information, refer to
Transmission Cooler, A/T.
9. Check the transmission fluid level.
Transmission Fluid Drain and Refill

2. Disconnect the transmission fluid cooler outlet tube from the transmission fluid cooler and
position it aside. For additional information, refer to
3. Attach a length of suitable drain hose to the transmission fluid cooler.
4. Insert the drain hose into a calibrated 10L (10.5 qt) container.
5. NOTICE: To prevent damage to the transaxle, do not run the engine above idle.
NOTE: If the transmission fluid return rate is less than 0.95L (1.0 qt) in 30 seconds, or if the return
hose pulsates, check for restrictions at the pump, transmission fluid cooler or transmission fluid
cooler tubes.
Run the engine at idle and pump out 3L (3.17 qt) of transmission fluid.
6. Switch the engine OFF.
7. Remove the transmission fluid level indicator from the transaxle filler tube.
8. Add 3L (3.17 qt) of transmission fluid to the transaxle.

cooler tubes.
14. Remove the length of drain hose from the transmission fluid cooler.
15. Connect the transmission fluid cooler outlet tube to the transmission fluid cooler. For additional
information, refer to Transmission Cooler, A/T.
16. Lower the vehicle.
18. Install the transmission fluid level indicator into the transaxle filler tube.
Run the engine.
20. Check the transmission fluid level and fill if necessary.

Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................

..................................................... 4.3 Liters (4.5 Qt)
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Engine Oil: Fluid Type Specifications
Engine Oil
Ford Part Name - Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) - Motorcraft SAE
5W-20 Full Synthetic Motor Oil (US) - Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) -
Motorcraft SAE 5W-20 Synthetic Motor Oil (Canada)
Ford Part Number - XO-5W20-QSP (US) - XO-5W20-QFS (US) - CXO-5W20-LSP12 (Canada) -

CXO-5W20-LFS12 (Canada)
Ford Specification - WSS-M2C930-A and API Certification Mark
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Power Steering Fluid Capacity
Fill between the MIN and MAX lines on reservoir

Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 1023
Power Steering Fluid: Fluid Type Specifications
POWER STEERING FLUID
Ford Part Name - Motorcraft MERCON V ATF
Ford Part Number - XT-5-QM
Ford Specification - MERCON V

Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
Item.......................................................................................................Motorcraft(R) R-134a
Refrigerant YN-19 (US); CYN-16-P or CYN-16-R (Canada) Specification...........................................
......................................................................................................................................................WS
H-M17B19-A Fill Capacity....................................................................................................................
..............................................................0.841 kg (29.6 oz) (1.85 lb)
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Refrigerant: Fluid Type Specifications
......................................................................................................................................................WS
..............................................................0.841 kg (29.6 oz) (1.85 lb)
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1029
Refrigerant: Testing and Inspection
Refrigerant Identification Testing
Refrigerant Identification
1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken
directly from the refrigeration system or storage
containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the
sample for testing.
2. The Refrigerant Blend Identifier with Printer will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The
weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital
display.
- If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm
will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22
and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The Refrigerant Blend Identifier with
Printer eliminates the effect of air when determining the refrigerant sample content because air is
not considered a contaminant, although air can affect A/C system performance. When the
Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is
98% or greater by weight) and air concentration levels are 2% or greater by weight, it will prompt
the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Contaminated Refrigerant Handling

NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered
refrigerant supply and may damage the recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system
flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in the area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
Refrigerant: Service and Repair
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C
refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment
manufacturer's procedures and instructions.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction
accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and
any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system.
Internal plumbing of these devices makes it impossible to correctly remove any foreign material.
These components are typically discarded after A/C system contamination. Hoses without mufflers
can normally be reused unless they are clogged with foreign material. The filter is intended for use
on one vehicle only.
1. NOTE: The filter inlet is marked with a label on one side of the filter body.
Orient the filter inlet toward the A/C condenser core.
2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for
low-pressure flushing and are not
designed for use with a charged refrigerant system. Do not make the condenser fitting connections
using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur.
NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the
end of this procedure.
Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2
halves of the fitting.
- Use flexible R-134a service hoses of 17,238 kPa (2,500 psi) burst rating.
- Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush
and Purge Fitting Kit.
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Heating and Air Conditioning/Service and Repair/Refrigerant Oil Adding.

4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Recovery, Evacuation and Charging.
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure
they do not interfere with other engine
compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C
operation and set the blower motor speed to maximum.
Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
7. Using a scan tool, command the idle to gradually bring the engine up to 1,200 rpm by running it
at lower rpms for short periods (first at 800 rpm,
then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system
operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging See: Heating and
Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the
condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation
and Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Item...............................................................................................................................................Moto
rcraft(R) PAG Refrigerant Compressor Oil YN-12-D Specification.......................................................
..........................................................................................................................................WSH-M1C2
31-B Fill Capacity.................................................................................................................................
...............................................................180 ml (6.09 fl oz)
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Refrigerant Oil: Fluid Type Specifications
Item...............................................................................................................................................Moto
..........................................................................................................................................WSH-M1C2
31-B Fill Capacity.................................................................................................................................
...............................................................180 ml (6.09 fl oz)
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1037
Refrigerant Oil: Service and Repair
Refrigerant Oil Adding

NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a
small amount is retained in each component. If certain components of the system are removed,
some of the PAG oil will go with the component. To maintain the original total oil charge, it is
necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the
total system PAG oil capacity must be added. b The amount specified may be used for one or
multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks
being repaired.
Adding Refrigerant Oil After A/C Compressor Replacement
Service A/C compressors shipped without clutch and pulley
1. Rotate the old A/C compressor shaft 6 to 8 revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the
same amount plus 30 ml (1 oz) of clean
PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into
the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz),
pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour
85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new
A/C compressor.
Service A/C compressors shipped with clutch and pulley
device.
- If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml
(4 oz) from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from
- If the amount of oil drained from the old A/C compressor is 118 ml (4 oz), remove 59 ml (2 oz)
from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0
ml (0 oz) from the new A/C compressor.
Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement
NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or
receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or
Thermostatic Expansion Valve (TXV) have also been installed due to system contamination, refer
to the appropriate heading.
1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain
the oil into a clean measuring cup.
2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and
60 ml (2 fl oz).
Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination
NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction
accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system
contamination and the A/C system has been flushed.
1. If the new A/C compressor is shipped with a new clutch and pulley already installed, remove the
shipping caps and rotate the new A/C compressor
shaft 6 to 8 revolutions while collecting the oil in a clean measuring cup.
2. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port.
3. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during
system charging. For the total PAG oil capacity
specification, refer to the Specifications table.
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the
PAG oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C)
System Recovery, Evacuation and Charging See:
Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System Recovery,
Evacuation and Charging.
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On
Injector Kit-Set to match the amount of refrigerant
compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the
refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and
Charging See: Heating and Air Conditioning/Service and Repair/Air Conditioning (A/C) System
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Component
Bleeding
Brake Bleeding: Service and Repair Component Bleeding
Component Bleeding
Master Cylinder
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions
will help prevent system contamination, brake component damage and the risk of serious personal
injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation. Master
cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
Failure to follow this instruction may result in serious personal injury.
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.
NOTE: When the brake master cylinder has been installed new or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
2. Remove the battery ground cable bolt and position the cable aside.
3. Loosen the Battery Junction Box (BJB) mounting screw.
4. Press the locking tab, disconnect the BJB from the bracket and position the BJB aside.
Bleeding > Page 1044
5. NOTE: The brake tubes must be installed in the same position and orientation as removed.
Disconnect the brake tube fittings at the master cylinder. Loosen the master cylinder brake tube
fittings at the Hydraulic Control Unit (HCU) to allow the brake tubes to move without being
damaged.
6. Install short brake tubes onto the primary and secondary ports with the ends submerged in a
container partially filled with clean, specified brake
fluid.
7. Have an assistant pump the brake pedal until clear fluid flows from the brake tubes without air
bubbles.
8. Remove the short brake tubes, and install the master cylinder brake tubes.
- Tighten the brake tube fittings to 23 Nm (17 lb-ft).
9. Position the BJB and engage the locking tab.
10. Tighten the BJB mounting screw.
11. Position the battery ground cable and install the bolt.
- Tighten the bolt to 10 Nm (89 lb-in).

13. Bleed the brake system. For additional information, refer to Brake System Bleeding See: Brake
System Bleeding.
Brake Caliper
injury.
water.
NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
1. Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the bleeder screw and submerge the
free end of the hose in a container partially filled with clean, specified brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder
screw. -
Repeat until clear, bubble-free fluid comes out.
- Refill the brake master cylinder reservoir as necessary.
4. Tighten the bleeder screw to specifications. Refer to Specifications. Remove the rubber hose
and install the bleeder screw cap.
5. Apply brakes several times to verify correct brake operation.
Wheel Cylinder
injury.
water.
NOTE: It is not necessary to do a complete brake system bleed if only the wheel cylinder was
screw. -

Brake Bleeding: Service and Repair Brake System Bleeding
Brake System Bleeding
Pressure Bleeding
injury.
water.
NOTE: Pressure bleed the brake system at 100-400 kPa (14.5-58 psi).
1. Clean all dirt from and remove the brake master cylinder filler cap and remove the filler cap.
- Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the RR bleeder screw and submerge the free end of the hose in a container
partially filled with clean, specified brake fluid.
4. Open the valve on the bleeder tank.
- Apply 100-400 kPa (14.5-58 psi) to the brake system.
5. Loosen the RR bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RR bleeder screw to specifications. Refer to
Specifications. Remove the rubber hose.
6. Continue bleeding the rest of the system, going in order from the LR bleeder screw to the RF
bleeder screw, ending with the LF bleeder screw.
- Tighten the brake caliper and wheel cylinder bleeder screws to specifications. Refer to
Specifications.
7. Close the bleeder tank valve. Remove the tank hose from the adapter and remove the adapter.
Fill the reservoir with clean, specified brake fluid
and install the reservoir cap.
Manual Bleeding
injury.
water.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap.
2. Remove the RR bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a
rubber drain hose to the RR bleeder screw and
submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
4. Loosen the RR bleeder screw until a stream of brake fluid comes out. While an assistant
maintains pressure on the brake pedal, tighten the RR
bleeder screw. -
5. Tighten the RR bleeder screw to specifications. Refer to Specifications. Remove the rubber hose
6. Repeat Steps 2 through 5 for the LR bleeder screw.
7. Remove the RF bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain hose to the RF bleeder screw and submerge
the free end of the hose in a container partially filled with clean, specified brake fluid.
9. Loosen the RF bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RF
bleeder screw. -
10. Tighten the RF bleeder screw to specifications. Refer to Specifications. Remove the rubber
hose and install the bleeder screw cap.
11. Repeat Steps 7 through 10 for the LF bleeder screw.

Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Supplemental Restraint System (SRS) Depowering and Repowering
Air Bag(s) Arming and Disarming: Service and Repair Supplemental Restraint System (SRS)
Depowering and Repowering
Depowering Procedure
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners or

adaptive load limiting retractors or probe the electrical connectors. Failure to follow this instruction
may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting
retractors which increases the risk of serious personal injury or death.
WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices.
Failure to follow this instruction may result in serious personal injury or death.
1. Turn all vehicle accessories OFF.
3. At the Central Junction Box (CJB), located below the LH side of the instrument panel, remove
RCM fuse 162 (7.5A) from the CJB. For additional
information, refer to the Wiring Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Number
4. Turn the ignition ON and monitor the air bag indicator for at least 30 seconds. The air bag
indicator will remain lit continuously (no flashing) if the
correct fuse has been removed. If the air bag warning indicator does not remain lit continuously,
remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. 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.
Disconnect the battery ground cable and wait at least one minute. For additional information, refer
to Battery.
Repowering Procedure
1. Turn the ignition from OFF to ON.
2. Install the RCM fuse 162 (7.5A) to the CJB.
3. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in front of
any air bag module when the battery is
connected. Failure to follow these instructions may result in serious personal injury in the event of
an accidental deployment.
Connect the battery ground cable.
Turn the ignition from ON to OFF. Wait 10 seconds, then turn the ignition back to ON and monitor
the air bag warning indicator with the air bag modules installed. The air bag warning indicator will
light continuously for approximately 6 seconds and then turn off. If an air bag SRS fault is present,
the air bag warning indicator will: - fail to light.
Supplemental Restraint System (SRS) Depowering and Repowering > Page 1054
- remain lit continuously. - flash. The air bag warning indicator may not illuminate until
approximately 30 seconds after the ignition has been turned from the OFF to the ON position. This
is the time required for the RCM to complete the testing of the SRS. If the air bag warning indicator
is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this
repaired. Clear all CMDTCs from the RCM and OCSM using a scan tool.
Deactivation and Reactivation
Supplemental Restraint System (SRS) Deactivation and Reactivation
Deactivation
4. Turn the ignition ON and monitor the air bag warning indicator for at least 30 seconds. The air
bag warning indicator will remain lit continuously
(no flashing) if the correct RCM fuse has been removed. If the air bag warning indicator does not
remain lit continuously, remove the correct RCM fuse before proceeding.
6. WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint
system (SRS) component and before servicing, removing, installing, adjusting or striking
components near the front or side impact sensors or the restraints control module (RCM). Nearby
components include doors, instrument panel, console, door latches, strikers, seats and hood
latches.
Refer to the Description and Operation portion of Restraint Systems for location of the RCM and
impact sensor(s).
To deplete the backup power supply energy, disconnect the battery ground cable and wait at least
1 minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Failure to follow these instructions may result in serious personal injury or death in the event of an
accidental deployment.
to Battery.
7. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module
See: Restraint Systems/Air Bag Systems/Air
Bag/Service and Repair/Driver Air Bag Module.
8. Partially remove the passenger air bag module. For additional information, refer to Passenger Air
Bag Module See: Restraint Systems/Air Bag
Systems/Air Bag/Service and Repair/Passenger Air Bag Module. -
Disconnect the 2 electrical connectors.

9. NOTE: Driver shown, passenger similar.
Under the front of the seats, loosen the bolt and disconnect the seat electrical bulkhead
connectors.
10. Install RCM fuse 162 (7.5A) to the CJB.
Reactivation
1. Remove RCM fuse 162 (7.5A) from the CJB.
2. Disconnect the battery ground cable and wait at least one minute. For additional information,
refer to Battery.
3. Install the driver air bag module. For additional information, refer to Driver Air Bag Module See:
Restraint Systems/Air Bag Systems/Air
4. Connect the 2 electrical connectors and install the passenger air bag module. For additional
information, refer to Passenger Air Bag Module See:
Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Passenger Air Bag Module.
5. Under the front of the seats, connect the seat electrical bulkhead connectors and tighten the bolt.
7. Connect the battery ground cable.
Connect the battery ground cable. For additional information, refer to Battery.
the air bag warning indicator will: - fail to light. - remain lit continuously. - flash. The air bag warning
indicator may not illuminate until approximately 30 seconds after the ignition has been turned from
the OFF to the ON position. This is the time required for the RCM to complete the testing of the
RCM. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a
pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault
discovered must be diagnosed and repaired. Clear all CMDTCs from the RCM and Occupant
Classification System Module (OCSM) using a scan tool.
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Battery Junction Box (BJB)
Fuse: Locations Battery Junction Box (BJB)
Battery Junction Box (BJB) > Page 1063
Fuse: Locations Central Junction Box (CJB)

Fuse: Locations Passenger Compartment Fuse Box
Fuse: Locations Power Distribution Box
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Battery Junction Box (BJB)
Fuse: Application and ID Battery Junction Box (BJB)
ID > Battery Junction Box (BJB) > Page 1071
Fuse: Application and ID Central Junction Box (CJB)

Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Battery Junction Box (BJB)
Fuse Block: Locations Battery Junction Box (BJB)
> Battery Junction Box (BJB) > Page 1078
> Battery Junction Box (BJB) > Page 1079
Fuse Block: Locations Central Junction Box (CJB)
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is
important to realize, however, that no attempt has been made on the diagrams to represent
components and wiring as they physically appear on the vehicle. For example, a 4-foot length of
wire is treated no differently in a diagram from one that is only a few inches long. Furthermore, to
aid in understanding electrical (electronic) operation, wiring inside complicated components has
been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one set. Other components that are
connected to the circuits may not be shown unless they influence the circuit operation.
Current Flow (1)
Each set normally starts with the component that powers the circuit, such as a fuse or the ignition
switch. Current flow is shown from the power source at the top of the diagram to ground at the
bottom of the diagram. A full representation of the power supply of a fuse or the power distribution
from a fuse to various components is given in the Power and Ground Distribution Diagrams. Full
representation of the ground connections are shown in the Power and Ground Distribution
Diagrams.
Switch Positions (2)
Within a diagram, all switches, sensors and relays are shown "at rest" (ignition switch OFF).
Splices (3)
Splices directly connecting to the power distribution are best represented on the power distribution
diagram in the Power and Ground Distribution Diagrams. Splices connected to grounds can be
seen completely in the Power and Ground Distribution Diagrams. For all other splices, a reference
is given to each off diagram where that particular splice can be best viewed.
Component Referencing (4)
Components on a diagram have a reference to a component location view or the diagram where it
is shown completely. The reference is located to the right of each component.
Component Names (5)
Component names are placed on the right hand side of each component when possible.
Descriptions of the internals of the component are also included when available. The diagram
where the component appears in full is listed in the Index. The base part number for a component
is listed in parentheses next to or under a component.
Internal Name and Function Identification Numbers (6)
Some components on each diagram have internal symbols with an identification number located
within it. You can identify the internal symbol or function by finding the corresponding number
under the component name.
> Diagram Information and Instructions > Page 1082
Circuit Numbering and Wire Identification (7)
Ford Motor Company uses three different circuit numbering conventions: Standard Circuit
Numbering System, Global Circuit Numbering System, and New Global Circuit Numbering System
(NGCNS). With each, the circuit number (which identifies a specific circuit function) is followed by
the wire color.
The wire identification consists of a basic color and possibly a stripe, and is determined directly
from the wire's circuit number. In the diagrams, the wire colors are indicated next to the wires. The
colors are abbreviated using the international norm IEC 757. The abbreviations are listed in set 4
"Symbols".
Fuse and Relay Information

Fuse/Locations and Relay/Locations contains a view of the fuse/relay box, in which fuses and
relays are identified, numbered and named. Fuse and relay numbering and naming follow the
indication of the fuse panel cover. In addition, for all removable relays, pin positions are added to
illustrate proper orientation.
Power Distribution
Power and Ground Distribution Diagrams shows the current feed circuits. The current path is
shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by
each fuse. The circuit is traced from the fuse to the component. All details (wires, splices,
connectors) between the fuse and the first component are shown.
Ground Distribution
Power and Ground Distribution Diagrams contains the diagram that shows the complete details for
each ground connection or main ground splice. This is useful in diagnosing a problem affecting
several components at once (poor ground connection or ground splice). All details (wires, splices,
connectors) between the ground point and the component are shown. These ground connection
details are shown here in order to keep the individual set diagrams as uncluttered as possible.
Component and Connector Information
Connector Views show the views of the pins and/or cavities of all connectors. The pin and cavity
sides are shown separately as if the connector were disconnected. The color of the connector
housing is indicated next to the connector number when available. The harness causal number is
located above the connector view and below the connector number. The circuit function charts are
located below each connector. The wiring harness designations are listed in Component Location
Charts.
Component Location Views shows the components and their connecting wires as they can be
found on the vehicle.
Locations information that can be found at the vehicle level will helps the user find where the
various items depicted on the diagram can physically be found on the vehicle. A brief written
description of the location is given, along with a reference to the component location views.
WARNINGS
- Always wear safety glasses for eye protection.
- Use safety stands whenever a procedure requires being under a vehicle.
- Be sure that the IGNITION SWITCH is always in the OFF position, unless otherwise required by
the procedure.
- Set the parking brake when working on any vehicle. An automatic transmission should be in
PARK. A manual transmission should be in NEUTRAL.
- Operate the engine only in a well-ventilated area to avoid danger of carbon monoxide.
- Keep away from moving parts, especially the fan and belts, when the engine is running.
- To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust
manifold, tail pipe, catalytic converter and muffler.
- Do not allow flame or sparks near the battery. Gases are always present in and around the
battery set. An explosion could occur.
- Do not smoke when working on a vehicle.
- To avoid injury, always remove rings, watches, loose hanging jewelry and avoid wearing loose
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Fuse Block: Diagnostic Aids
Troubleshooting wiring harness and connector hidden concerns
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Terminal not properly seated
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
5 = Intermittent contact
6 = Unlocked terminal (Hidden by wire seal)
7 = Seal
Check for unlocked terminal by pulling each wire at the end of the connector.
Defective insulation stripping
1 = Proper crimp
2 = Insulation not removed
3 = Wire strands missing
4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Deformed (enlarged) female terminals
1 = Enlarged
2 = Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent
signal.
Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical short inside the harness
1 = Solder coated wire to ground

2 = Harness protective tape
3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Electrical short within the harness
Splice tape removed 1
= Intermittent short
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape
2 = Wiring strand
3 = Broken strands intermittent signal
4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Recommended splicing method - Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable. 2. Strip wires to appropriate length.

3. lnstall heat shrink tubing. 4. Twist wires together. 5. Solder wires together.
NOTE: -
Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
- Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seat wire splice.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.

8. Use shielded heat gun to heat the repaired area until adhesive flows Out of both ends of heat
shrink tubing. 9. Reconnect battery ground cable.
Recommended splicing method - Crimp (For 10-22 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable. 2. Strip 6.35mm (1/4 in) of insulation from each wire end,
taking care not to nick or cut wire strands. 3. Install heat shrink tubing.
NOTE: Use heat shrinkable tubes marked with ES-1 (16-22 GA) or ES-2 (10-18 GA) to seal wire
splice.
4. Select appropriate wire splice for the wires to be spliced. 5. Identify the appropriate crimping
chamber on the Rotunda 164-R5901 Pro-Crimper by matching the wire size on the dies with the
wire size
stamped on the butt splice.
NOTE: Rotunda 164-R5901 Pro-Crimper is the only tool that can be used with these splices.
6. Center one end of the wire splice in the appropriate crimping chamber. 7. If visible, be sure to
place the brazed seam toward the indenter. 8. Insert stripped wire into the barrel. 9. Holding the
wire in place, barrel squeeze tool handles appropriate ratchet releases.
10. Repeating steps 5-7, crimp the other half of the splice.
11. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice b. Wire insulation does not enter butt
splice. c. Wire is visible through inspection hole of splices.
12. Evenly position supplied heat shrink tubing over wire repair. 13. Use shielded heat gun to heat
the repaired area until adhesive flows out of both ends of the heat shrink tubing. 14. Reconnect
battery ground cable.
The given chart is to be used when pigtails or terminals are different wire gauge than the vehicle
harness.
Fuse Block: Connector Views

Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Page 1108
Relay Box: Diagrams

Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Battery Junction Box (BJB)
and ID > Battery Junction Box (BJB) > Page 1111

Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
The MIL notifies the driver the powertrain control module (PCM) has detected an on board
diagnostic (OBD) emission-related component or system concern. When this occurs, an OBD
diagnostic trouble code (DTC) sets.
- The MIL is located in the instrument cluster (IC) and is labeled CHECK ENGINE, SERVICE
ENGINE SOON or the international standards organization (ISO) standard engine symbol.
- The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds.
- The MIL remains illuminated after instrument cluster prove out if: -
an emission-related concern and DTC exists.
- the PCM does not send a control message to the instrument cluster (applications with the MIL
controlled through the communication link).
- the PCM is operating in the hardware limited operation strategy (HLOS).
- The MIL remains off during the instrument cluster prove out if an indicator or instrument cluster
concern is present.
- To turn off the MIL after a repair, a reset command from the scan tool must be sent, or 3
consecutive drive cycles must be completed without a concern.
- For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures
- If the MIL flashes at a steady rate, a severe misfire condition may exist.
- If the MIL flashes erratically, the PCM can reset while cranking if the battery voltage is low.
- The MIL flashes after a period of time with the ignition in the RUN position (engine not running) if
DTC P1000 is set.
Check Engine, Service Engine Soon, Or ISO Standard Engine Symbol

Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and
Repair
Vehicle Lifting: Service and Repair
Jacking and Lifting
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or
jackstand. Failure to follow this instruction may result in serious personal injury.
WARNING: Position the hoist lift arms as shown in the illustration. Incorrect positioning could result
in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in serious
personal injury.
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the
parking brake if the rear wheels will remain on the ground. These actions help prevent unintended
vehicle movement. Failure to follow these instructions may result in serious personal injury.
NOTICE: Damage to the suspension, exhaust or steering linkage components may occur if care is
not exercised when positioning the hoist adapters prior to lifting the vehicle.
Jacking and Lifting Locations

Ford Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Module > Component Information > Locations
Module > Component Information > Locations > Page 1126

Removal
damage may result.
to Information Bus.
Installation

System (TPMS) Sensor Training See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes.
Ford Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Training
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire
Monitoring System/Testing and Inspection/Programming and Relearning.
illuminate.
position.
position.
successfully.
vehicle doors open.

Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training >
Page 1137
repeated.
Page 1138
Activation
stem.
vehicle doors open.
Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom
Related Diagnostic Procedures
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module >

Removal
damage may result.
to Information Bus.
Installation

System (TPMS) Sensor Training See: Testing and Inspection/Monitors, Trips, Drive Cycles and
Readiness Codes.
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Training
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Testing and
illuminate.
position.
position.
successfully.
vehicle doors open.

Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1153
repeated.
Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page 1154
Activation
stem.
vehicle doors open.
Chart in Diagnosis and Testing. See: Testing and Inspection/Symptom Related Diagnostic
Procedures
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Wheel Bearing and Wheel Hub

Repair > Front Suspension > Page 1159
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and
Suspension/Steering/Front Steering
Knuckle/Service and Repair.
2. Remove and discard the snap ring.
3. NOTE: If removing the wheel hub, a new wheel bearing must be installed. The bearing inner
race may remain on the wheel hub.
Using the Bushing Remover/Installer and Bearing Puller, remove the wheel hub.
4. NOTICE: The special tools must be used to prevent damage to the hub. If the hub is damaged, a
new hub must be installed.
NOTICE: Do not use heat to remove the bearing inner ring or damage to the bearing may occur.
NOTE: This step is necessary if the inner wheel bearing race remains on the wheel hub after
removing the wheel hub.
Using the Bushing Remover/Installer and Bearing Puller, remove the bearing inner race from the
wheel hub.
5. Using the Axle Shaft Bearing Cup Installer and Wheel Speed Sensor Ring Installer, remove the
bearing from the wheel knuckle.
Installation
1. NOTICE: Once the wheel bearing is installed, make sure the wheel speed sensor ring on the
bearing and the sensor hole on the wheel
knuckle are clean or damage to the wheel speed sensor or sensor ring may occur.
NOTICE: Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed
sensor ring (black in color) toward the inner face of the wheel knuckle.
Using the Tri-Beam Suspension Service Set Adapter, install the new wheel bearing.
2. Using the Bearing Cup Remover/Installer and the Drive Pinion Bearing Cup Installer, install the
wheel hub.
3. NOTE: Make sure the wheel speed sensor hole in the wheel knuckle is not blocked by the snap
ring. The sensor hole must be positioned between
the ends of the snap ring.
Install the new snap ring.
4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and

Wheel Bearing: Service and Repair Rear Suspension
1. Remove the brake drum. For additional information, refer to Drum Brake System.
2. Remove the dust cap.
3. Remove and discard the wheel hub nut.
- To install, tighten the new nut to 340 Nm (251 lb-ft).
4. Remove the wheel bearing and wheel hub.

Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Wheel Bearing and Wheel Hub (Rear Suspension)
To install, tighten the new wheel hub nut

to..............................................................................................................................................340 Nm
(251 lb-ft).
Wheel Knuckle (Front Suspension)
NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be
tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will
occur if the wheel bearing is loaded with the weight of the vehicle applied.
NOTICE: Install and tighten the new wheel hub nut to specification in a continuous rotation. Always
install a new wheel hub nut after loosening or when not tightened to specification in a continuous
rotation or damage to the component may occur.
NOTE: Apply the brake to keep the halfshaft from rotating.
Install the new wheel hub nut. Tighten to.............................................................................................

...............................................................280 Nm (207 lb-ft) in a continuous rotation.
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Tighten the wheel nuts in a star/cross pattern

to............................................................................................................................................90 Nm
(66 lb-ft).
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Studs
Removal
1. NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may
result in major service expense. New parts must be installed with the same part numbers or
equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to make sure of
correct retention of these parts.
NOTE: Make sure the steering wheel is in the UNLOCKED position.
Remove the brake disc. For additional information, refer to Disc Brake System.
2. Using the C-Frame and Screw Installer/Remover, remove the wheel stud.
Installation
1. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to
allow the wheel stud to fully seat against the hub flange.
Position the wheel stud in the flange, making sure the serrations on the stud line up with the
serrations in the flange. Install the washers and a wheel nut.
2. NOTICE: Do not use power tools to install the wheel stud or damage to the flange may occur.
Tighten the wheel nut until the stud is seated against the hub flange.
3. Remove the wheel nut and the washers. Discard the wheel nut.
4. Install the brake disc. For additional information, refer to Disc Brake System.
Wheel Fastener: Service and Repair Rear Suspension
Wheel Studs
NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to make sure of correct retention of these parts.
NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result.
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made
by the original wheel stud.
- Place approximately 4 washers over the outside end of the wheel stud and thread a standard
wheel nut onto the wheel stud with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub
flange.
4. Remove the wheel nut and washers.
5. Install the brake drum. For additional information, refer to Drum Brake System.
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair
Jacking and Lifting
personal injury.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation
Variable Valve Timing Actuator: Description and Operation
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM
Overview
The VCT system enables rotation of the camshaft(s) relative to the crankshaft rotation as a function
of engine operating conditions. There are 4 types of VCT systems. -
Exhaust phase shifting (EPS) system - the exhaust cam is the active cam being retarded.
- Intake phase shifting (IPS) system - the intake cam is the active cam being advanced.
- Dual equal phase shifting (DEPS) system - both intake and exhaust cams are phase shifted and
equally advanced or retarded.
- Dual independent phase shifting (DIPS) system - where both the intake and exhaust cams are
shifted independently.
All systems have 4 operational modes: idle, part throttle, wide open throttle (WOT), and default
mode. At idle and low engine speeds with closed throttle, the powertrain control module (PCM)
determines the phase angle based on air flow, engine oil temperature and engine coolant
temperature. At part and wide open throttle the PCM determines the phase angle based on engine
RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine
power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque.
In addition, some VCT system applications can eliminate the need for an external exhaust gas
recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the
overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS
and DEPS systems are used.
The VCT system knocking and noise concerns are diagnosed in the diagnostic/repair information.
For additional information, refer to the Engine, Engine System - General Information. Verification of
incorrect VCT phasing on a warm engine operating below 1500 RPM can be isolated using a
stethoscope and by monitoring the VCTADV, VCTADVERR and VCTDC PIDs using a scan tool. If
the VCT phaser does not maintain correct valve timing, low oil pressure or oil flow restrictions are
primary possible causes. Verify correct oil pressure and flow, refer to the Engine, Engine System -
General Information.
Variable Camshaft Timing (VCT) System
The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position
(CMP) sensor, and a trigger wheel. The CMP sensor trigger wheel indicates the CMP signal for
that bank. A crankshaft position (CKP) sensor provides the PCM with crankshaft positioning
information in 10 degree increments.
1. The PCM receives input signals from the intake air temperature (IAT), engine coolant
temperature (ECT), engine oil temperature (EOT), CMP,
throttle position (TP), mass air flow (MAF), and CKP sensors to determine the operating conditions
of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft
position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft
position is determined by engine RPM, load and throttle position. The VCT system does not
operate until the engine is at normal operating temperature.
2. The VCT system is enabled by the PCM when the correct conditions are met. 3. The CKP signal
is used as a reference for CMP positioning. 4. The VCT solenoid valve is an integral part of the
VCT system. The solenoid valve controls the flow of engine oil in the VCT actuator assembly.
As the PCM controls the duty cycle of the solenoid valve, oil pressure/flow advances or retards the
cam timing. Duty cycles near 0% or 100% represent rapid movement of the camshaft. Retaining a
fixed camshaft position is accomplished by dithering (oscillating) the solenoid valve duty cycle.
The PCM calculates and determines the desired camshaft position. It continually updates the VCT
solenoid duty cycle until the desired position is achieved. A difference between the desired and
actual camshaft position represents a position error in the PCM VCT control loop. The PCM
disables the VCT and places the camshaft in a default position if a concern is detected. A related
DTC is also set when the concern is detected.
5. When the VCT solenoid is energized, engine oil is allowed to flow to the VCT actuator assembly
which advances or retards the camshaft timing.
One half of the VCT actuator is coupled to the camshaft and the other half is connected to the
timing chain. Oil chambers between the 2 halves
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 1183
couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the
chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either
an advance or retard position depending on the oil flow.
VCT System
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System
Diagnosis > Compression Test
Engine
Compression Test

Diagnosis > Compression Test > Page 1189
Diagnosis > Compression Test > Page 1190
Engine
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Using the flats on the camshafts to prevent camshaft rotation, tighten the camshaft drive gear bolts.
Tighten to..............................................................................................................................................
.........................................................72 Nm (53 lb-ft).
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > Procedures
Camshaft: Procedures
Camshaft Journal To Bearing Clearance - OHC Engines
Camshaft Journal to Bearing Clearance - OHC Engines
NOTE: Refer to the appropriate Engine for the specification.
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal
clearance.
Measure each camshaft bearing in 2 directions.
- Subtract the camshaft journal diameter from the camshaft bearing diameter.
Camshaft End Play - OHC Engines
Camshaft End Play - OHC Engines
1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
- If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
- If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.
Camshaft Surface Inspection
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable
outside the contact area.
> Component Information > Service and Repair > Procedures > Page 1199
Camshaft Bearing Journal Diameter
Camshaft Bearing Journal Diameter
1. Measure each camshaft journal diameter in 2 directions.
Camshaft Lobe Lift
Camshaft Lobe Lift
1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
- Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading to figure the camshaft lobe lift.
Camshaft Runout
Camshaft Runout
1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
- Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading.
Camshaft: Removal and Replacement
Valve Train Components - Exploded View
Camshafts
Camshafts
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material
(including any material created while cleaning gasket surfaces) that enters the oil passages,
coolant passages or the oil pan can cause engine failure.
NOTICE: Do not rotate the camshafts unless instructed to in this procedure. Rotating the
camshafts or crankshaft with timing components loosened or removed can cause serious damage
to the valves and pistons.
2. Remove the coolant expansion tank. For additional information, refer to Cooling System &/or
Engine Block Heater.
3. Remove the RF wheel and tire. For additional information, refer to Wheels and Tires.
4. Check the valve clearance. For additional information, refer to Valve Clearance Check See:
Adjustments.
5. Remove the accessory drivebelt. For additional information, refer to Drive Belts, Mounts,
Brackets and Accessories.
6. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to
the engine. Turn the engine in the
normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top
Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.
7. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to
prevent engine rotation can result in engine
damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
8. Remove the engine plug bolt.
9. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning
past TDC. However, the crankshaft can still be
rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during
the camshaft removal and installation.
Install the Crankshaft TDC Timing Peg.

Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front
cover.
11. Remove the front cover lower timing hole plug from the engine front cover.
12. Remove the front cover upper timing hole plug from the engine front cover.
13. Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.
14. NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to
collapse and create slack in the timing chain.
Installing an M6 x 30 mm bolt into the upper front cover timing hole will hold the tensioner arm in a
retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft
gear.
Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole.
- Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to
collapse the timing chain tensioner plunger.
- Insert an M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in
place.
15. Remove the Camshaft Alignment Plate.
16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust
camshaft drive gear.
17. Remove the timing chain from the intake camshaft drive gear.
18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake
camshaft drive gear.
19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
20. NOTICE: Failure to follow the camshaft loosening procedure can result in damage to the
camshafts.
NOTE: Mark the location and orientation of each camshaft bearing cap.
Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
- Repeat the first step until all tension is released from the camshaft bearing caps.
- Remove the camshaft bearing caps.
- Remove the camshafts.
Installation
1. NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the
Camshaft Alignment Plate can be installed
without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position
as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or
installing the camshafts 180 degrees out of position can cause severe damage to the valves and
pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing
caps in the sequence shown in 3 stages:
- Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger-tight.
- Stage 2: Tighten to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (142 lb-in).

2. Install the Camshaft Alignment Plate.
3. Install the intake camshaft drive gear and hand-tighten the bolt.
4. Install the timing chain on the intake camshaft drive gear.
5. NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing
sprocket and the intake camshaft drive gear in order to
install the exhaust camshaft drive gear onto the exhaust camshaft.
Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the
exhaust camshaft.
- Hand-tighten the bolt.
6. NOTE: Releasing the tensioner arm will remove the slack from the timing chain release.
Remove the M6 x 30 mm bolt from the upper front cover timing hole to unlock the tensioner arm.
damage.
11. Install the front cover upper timing hole plug.
12. Apply silicone gasket and sealant to the threads of the front cover lower timing hole plug.
- Install the plug and tighten to 12 Nm (106 lb-in).

13. Install the engine plug bolt.
14. Install the accessory drivebelt. For additional information, refer to Drive Belts, Mounts, Brackets
and Accessories.
15. Install the RF wheel and tire. For additional information, refer to Wheels and Tires.
16. Install the valve cover. For additional information, refer to Valve Cover See: Service and
Repair/Removal and Replacement/Valve Cover.
17. Install the coolant expansion tank. For additional information, refer to Cooling System &/or
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures
Lifter / Lash Adjuster: Procedures
Valve Tappet Inspection
1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident,
inspect the camshaft lobes and valves for damage.
Install new components as necessary.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 1213
Lifter / Lash Adjuster: Removal and Replacement

Valve Tappets
Valve Tappets
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.
2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft/Service
and Repair/Removal and Replacement/Camshafts.
3. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve
tappets to make sure they are assembled in their
original positions.
NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For
example, a tappet with the number 0.650 has the thickness of 3.650 mm.
Remove and inspect the valve tappets. For additional information, refer to Engine.
- Coat the valve tappets with clean engine oil prior to installation.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Diagrams
Rocker Arm Assembly: Diagrams

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation
Overview
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Page 1220
VCT System
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Connecting Rod Bearing: Service and Repair
Bearing Inspection
1. Inspect bearings for the following defects:
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating
3. Imbedded dirty engine oil
4. Scratching - dirty engine oil
5. Base exposed - poor lubrication
6. Both edges worn - journal damaged
7. One edge worn - journal tapered or bearing not seated

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications

Component Information > Specifications > Page 1228
a No. 3 Journal - Supported by No. 1 and No. 5 journals.
Rod Bearing Cap
Install the connecting rod caps and bolts. Tighten the bolts in 2 stages. Stage 1: Tighten to..............
..............................................................................................................................................................
.............29 Nm (21 lb-ft). Stage 2: Tighten an additional......................................................................
...........................................................................................................90 degrees.
Component Information > Service and Repair > Connecting Rod-To-Piston Clearance
Connecting Rod: Service and Repair Connecting Rod-To-Piston Clearance
Connecting Rod-to-Piston Clearance
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston.
Verify the measurement is within specification.
Component Information > Service and Repair > Connecting Rod-To-Piston Clearance > Page 1231
Connecting Rod: Service and Repair Connecting Rod Bearing Journal-To-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing.

Connecting Rod: Service and Repair Connecting Rod Bearing Journal Taper and Out-Of-Round
Connecting Rod Bearing Journal Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one
another at each end of the connecting rod journal.
The difference in the measurements from one end to the other is the taper. Verify measurement is
within the wear limit.
Connecting Rod: Service and Repair Connecting Rod Bend
Connecting Rod Bend
1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture.
Follow the instructions of the fixture manufacturer.
Verify the bend measurement is within specification.

Connecting Rod: Service and Repair
Connecting Rod-To-Piston Clearance
Connecting Rod-to-Piston Clearance
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the piston.
Verify the measurement is within specification.
Connecting Rod Bearing Journal-To-Bearing Clearance
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the
connecting rod bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage
should be smooth and flat. A changing width indicates
a tapered or damaged connecting rod or connecting rod bearing.

Connecting Rod Bearing Journal Taper and Out-Of-Round
Connecting Rod Bearing Journal Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one
another at each end of the connecting rod journal.
The difference in the measurements from one end to the other is the taper. Verify measurement is
within the wear limit.
Connecting Rod Bend
Connecting Rod Bend
1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture.
Follow the instructions of the fixture manufacturer.
Verify the bend measurement is within specification.
Connecting Rod Bushing Diameter
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Crankshaft Main Bearing: Specifications
a No. 3 Journal - Supported by No. 1 and No. 5 journals.

Main Bearing Cap
Install and tighten the 10 main bearing beam bolts. Tighten the bolts in the sequence shown in 3
stages. Stage 1: Tighten to...................................................................................................................
.......................................................................5 Nm (44 lb-in). Stage 2: Tighten to..............................
...........................................................................................................................................................2
5 Nm (18 lb-ft). Stage 3: Tighten an additional.....................................................................................
............................................................................................90 degrees.
Crankshaft Main Bearing: Service and Repair
Bearing Inspection
1. Inspect bearings for the following defects:
1. Cratering - fatigue failure
2. Spot polishing - incorrect seating
3. Imbedded dirty engine oil
4. Scratching - dirty engine oil
5. Base exposed - poor lubrication
6. Both edges worn - journal damaged
7. One edge worn - journal tapered or bearing not seated

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-Of-Round
Crankshaft: Service and Repair Crankshaft Main Bearing Journal Taper and Out-Of-Round
Crankshaft Main Bearing Journal Taper and Out-of-Round
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each
end of the main bearing journal.
Component Information > Service and Repair > Crankshaft Main Bearing Journal Taper and Out-Of-Round > Page 1248
Crankshaft: Service and Repair Crankshaft Main Bearing Journal-To-Bearing Clearance
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal
clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.

Crankshaft: Service and Repair Crankshaft End Play
Crankshaft End Play
1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Crankshaft: Service and Repair Crankshaft Main Bearing Journal Diameter
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Engine Block Heater: Service and Repair
Block Heater
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding See: Cooling System/Service and
Repair/Cooling System Draining, Filling and Bleeding.
2. NOTE: Make sure that the block heater wiring is routed and secured away from rotating or hot
components, or damage to the wiring can occur.
Disconnect the block heater electrical connector.
3. Remove the block heater.
5. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding See: Cooling
System/Service and Repair/Cooling System Draining, Filling and Bleeding.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in
drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: Stage 1:
Tighten to..............................................................................................................................................
.........................................100 Nm (74 lb-ft). Stage 2: Tighten an additional........................................
.............................................................................................................90 degrees (one-fourth turn).
Crankshaft Pulley > Component Information > Service and Repair > Crankshaft Pulley and Crankshaft Front Seal -
Exploded View
Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley and Crankshaft
Front Seal - Exploded View
Lower End Components - Exploded View
Crankshaft Pulley and Crankshaft Front Seal

Exploded View > Page 1259
Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley
Crankshaft Pulley
Removal
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools
as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not
keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together
by friction, using diamond washers between the flange faces on each part. For that reason, the
crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring
loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in
place by the special service tools, otherwise severe engine damage can occur.
2. Remove the RH wheel and tire. For additional information, refer to Wheels and Tires.
3. Remove the accessory drive belt. For additional information, refer to Drive Belts, Mounts,
4. Remove the valve cover. For additional information, refer to Valve Cover See: Service and
5. NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to
the engine. Turn the engine in the
normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top
Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.

damage.
NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Plate cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
7. Remove the engine plug bolt.
8. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning
past TDC. However, the crankshaft can still be
rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during
the crankshaft pulley removal and installation.
Install the Crankshaft TDC Timing Peg.
9. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during removal of
the pulley bolt or damage to the engine
can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper
Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The
diamond washer must be replaced. Remove and discard the diamond washer. If the diamond
washer is not installed, engine damage may occur.
Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the
crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.
Installation
1. Install a new diamond washer.
2. NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock
position.
3. NOTICE: Only hand-tighten the 6 mm bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
cover.
4. NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation
of the pulley bolt or damage to the
engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft
Damper Holding Tool and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in
drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees (one-fourth turn).

8. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.
9. Install the Crankshaft TDC Timing Peg.
10. NOTE: Only turn the engine in the normal direction of rotation.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this
procedure.
12. Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be
corrected by repeating this procedure.

16. Install the engine plug bolt.
17. Install the valve cover. For additional information, refer to Valve Cover See: Service and
18. Install the accessory drive belt. For additional information, refer to Drive Belts, Mounts,
19. Install the RF wheel and tire. For additional information, refer to Wheels and Tires.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Procedures
Piston: Procedures
Piston Inspection
Piston Inspection
NOTICE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can
occur.
1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If
wear marks, scores or glazing is found on the piston
skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
- Make sure the oil ring holes are clean.
Piston Pin Bore Diameter
Piston Pin Bore Diameter
1. NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within
specification.
Piston Diameter
Piston Diameter

Component Information > Service and Repair > Procedures > Page 1269
1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the
top of the piston at the point indicated.
Piston To Cylinder Bore Clearance
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston Selection
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting
a piston.
1. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based
on their relative position within the range. A paint
spot or specific size grade on a new piston indicates the position within the size range.
Choose the piston with the correct paint color or specific size grade.
Piston Ring End Gap
Piston Ring End Gap
NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The cylinder bore must be within specification for taper and out-of-round.
1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring
end gap.
Piston Ring-To-Groove Clearance
Piston Ring-to-Groove Clearance
1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Piston Pin Diameter

Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
Piston: Overhaul
Piston
Disassembly
1. Remove the piston rings from the piston.
- Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.
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. For additional information, refer to Engine.
Assembly
1. NOTE: The arrow on the top of the piston points towards the front of the engine.
Align the piston-to-connecting rod orientation marks, and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. NOTE: The piston compression upper and lower ring should be installed with the paint mark on
the outside diameter circumference of the ring to
be positioned on the right side of the ring gap. The lower compression ring can also be installed
with the undercut side downward.
NOTE: The upper and lower compression ring gaps are not controlled for installation.
Install the piston rings onto the piston as shown.
1. Piston pin
2. Upper oil control ring gap location
3. Lower oil control ring gap location
4. Center line of the piston pin bore and the expander gap
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
intake: 0.25 mm (0.0095 in).
- exhaust: 0.30 mm (0.0115 in).
intake: 0.22-0.28 mm (0.008-0.011 in).
- exhaust: 0.27-0.33 mm (0.010-0.013 in).
location.
Components - Exploded View See: Camshaft, Lifters and Push Rods/Camshaft/Service and
Repair/Removal and Replacement/Valve Train Components - Exploded View and Valve Tappets
See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and
Replacement/Valve Tappets.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Diagrams
Rocker Arm Assembly: Diagrams

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair
Valve Cover: Service and Repair
Valve Cover
Valve Cover (View 1 of 2)
Valve Cover (View 2 of 2)

Information > Service and Repair > Page 1287
Removal
2. Disconnect the 4 ignition coil-on-plug electrical connectors.
3. Remove the 4 ignition coil-to-valve cover bolts and the ignition coils.
4. Lift up the connector boot and disconnect the Cylinder Head Temperature (CHT) sensor
electrical connector.
5. Disconnect the crankcase breather tube from the valve cover.
6. Detach the 6 wiring harness retainers from the valve cover stud bolts.
7. Disconnect the generator electrical connector.
8. Remove the radio interference capacitor bracket bolt.
9. Remove the radio interference capacitor ground bolt and position the bracket aside.
10. Remove the 14 valve cover retainers, the valve cover and gasket.
- Discard the valve cover gasket.
Installation
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths.

Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the locations shown.
3. NOTE: The valve cover must be secured within 4 minutes of silicone gasket application. If the
valve cover is not secured within 4 minutes, the
sealant must be removed and the sealing area cleaned with metal surface prep.
Install the valve cover, a new gasket and the 14 retainers.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
4. Position the radio interference capacitor bracket and install the bolt.
5. Install the radio interference capacitor ground bolt.
6. Connect the generator electrical connector.

7. Attach the 6 wiring harness retainers to the valve cover stud bolts.
8. Connect the crankcase breather tube on the valve cover.
9. Connect the CHT sensor electrical connector and install the connector boot.
10. Install the ignition coils and the 4 ignition coil-to-valve cover bolts.
11. Connect the 4 ignition coil-on-plug electrical connectors.
12. Connect the CMP sensor electrical connector.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Valve Guide: Service and Repair
Valve Guide Inner Diameter
1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into
the combustion chamber side of the valve guide, if
necessary.
Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top,
middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve Seat Width
Valve Seat: Service and Repair Valve Seat Width
Valve Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
- Measure the intake valve seat width.
- Measure the exhaust valve seat width.
- Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Service and Repair > Valve Seat Width > Page 1296
Valve Seat: Service and Repair Valve Seat Runout
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures
Valve Spring: Procedures
Valve Spring Installed Length
Valve Spring Installed Length
1. Measure the installed length of each valve spring.
Valve Spring Free Length
Valve Spring Free Length
1. Measure the free length of each valve spring.
Valve Spring Strength
Valve Spring Strength
1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
Information > Service and Repair > Procedures > Page 1301
Valve Spring: Removal and Replacement
Valve Springs
Valve Springs
Removal
2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters
and Push Rods/Camshaft/Service and
Repair/Removal and Replacement/Camshafts.
original positions.
4. Remove the spark plugs. For additional information, refer to Ignition System.
5. NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed
air from the cylinder until the valve spring,
valve spring retainer and valve collet is installed. Any loss of air pressure will allow the valve to fall
into the cylinder.
Connect the compressed air supply to cylinder No. 1.
6. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
- Using the Valve Spring Compressors, compress the valve spring and remove the valve collet,
using some multi-purpose grease and a small screwdriver.
- Remove the valve spring retainer and the valve spring.
Installation
1. NOTE: Check the seating of the valve collet.
Using the Valve Spring Compressors, install the valve spring.
- Insert the valve spring and the valve spring retainer.
- Compress the valve spring and install the valve collet using some grease and a small screwdriver.
2. Disconnect the compressed air supply.
3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to Ignition System.
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and
Push Rods/Camshaft/Service and Repair/Removal
and Replacement/Camshafts.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Valve Stem Diameter
Valve: Service and Repair Valve Stem Diameter
Valve Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the
diameter is within specification.
Component Information > Service and Repair > Valve Stem Diameter > Page 1308
Valve: Service and Repair Valve Inspection
Valve Inspection
1. Inspect the following valve areas:
1. The end of the stem for grooves or scoring.
2. The valve face and the edge for pits, grooves or scores.
3. The valve head for signs of burning, erosion, warpage and cracking.
4. The valve margin for wear.

Component Information > Service and Repair > Valve Stem Diameter > Page 1309
Valve: Service and Repair Valve Stem To Valve Guide Clearance
Valve Stem to Valve Guide Clearance

NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve
guide clearance.
1. NOTE: If necessary, use a magnetic base.
Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture
and zero the Dial Indicator Gauge. Move the
Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note
the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Drive Belt: Service and Repair Front End Accessory Drive (FEAD) - Exploded View

Belt > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1315
Drive Belt: Service and Repair Accessory Drive Belt
Accessory Drive Belt
accessory drive belt.

Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Drive Belt Tensioner: Service and Repair Front End Accessory Drive (FEAD) - Exploded View

Belt Tensioner > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View >
Page 1320
Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner
Accessory Drive Belt Tensioner
accessory drive belt from the tensioner.
4. NOTE: The accessory drive belt tensioner must be replaced as a complete unit.
Remove the 2 bolts and the accessory drive belt tensioner.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Procedures
Engine Mount: Procedures
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate system and procedure for special instructions on loosening and
tightening mount fasteners.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may
occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the
same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
8. Test the system for normal operation.

Engine Mount > Component Information > Service and Repair > Procedures > Page 1325
Engine Mount: Removal and Replacement
Engine Mount
Coolant Degas Bottle
Engine Mount
Engine Mount > Component Information > Service and Repair > Procedures > Page 1326
1. Remove the degas bottle bolt.
2. Lift the coolant degas bottle off of the shock tower bracket and position it aside.
3. Install the Engine Support Bar.
4. Remove the 2 engine mount nuts.
5. Remove the 3 bolts and the engine mount.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View
Idler Pulley: Service and Repair Front End Accessory Drive (FEAD) - Exploded View

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Front End Accessory Drive (FEAD) - Exploded View > Page 1331
Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley
Accessory Drive Belt Idler Pulley
accessory drive belt from the idler pulley.
4. Remove the bolt and accessory drive belt idler pulley.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Specifications
Oil pressure (hot @ 2,000 rpm)............................................................................................................

..............................................200-268 kPa (29-39 psi)
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Testing and Inspection
Engine
Oil Pressure Test
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure switch oil galley port.
3. Run the engine until normal operating temperature is reached.
4. Run the engine at the specified rpm and record the gauge reading.
5. The oil pressure should be within specifications; refer to the specification chart in the appropriate
engine system.
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

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Service and Repair > Engine Lubrication Components - Exploded View
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Engine Lubrication Components -
Exploded View
Transaxle Bolts for Oil Pan Removal

Tube > Component Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1341
Oil Pan, Oil Pump Screen and Pickup Tube
Oil Pump
Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube
Oil Level Indicator and Tube
1. Remove the oil level indicator.
2. Remove the oil level indicator tube bolt.
3. Detach the wiring harness retainer from the oil level indicator tube.
4. Remove the oil level indicator tube and discard the O-ring seal.
- To install, lubricate the new O-ring seal with clean engine oil.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................

..................................................... 4.3 Liters (4.5 Qt)
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1348
Engine Oil: Fluid Type Specifications
Engine Oil
Ford Part Name - Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) - Motorcraft SAE
5W-20 Full Synthetic Motor Oil (US) - Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) -
Motorcraft SAE 5W-20 Synthetic Motor Oil (Canada)
Ford Part Number - XO-5W20-QSP (US) - XO-5W20-QFS (US) - CXO-5W20-LSP12 (Canada) -

CXO-5W20-LFS12 (Canada)
Ford Specification - WSS-M2C930-A and API Certification Mark
Note: Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Oil Cooler: Service and Repair
Oil Cooler
2. Remove the oil drain plug and drain the engine oil.
3. Remove and discard the oil filter.
- To install, tighten three-fourths of a turn after the filter gasket makes contact with the oil filter
adapter.
4. Drain the engine cooling system. For additional information, refer to Cooling System &/or Engine
Block Heater.
5. Disconnect the 2 coolant hoses from the oil cooler.
6. Disconnect the Engine Oil Pressure (EOP) electrical connector.
7. NOTE: Discard the gasket.
Remove the 4 bolts and the oil filter adapter.
8. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist.
To diagnose mechanical concerns, refer
to Engine.
Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler. -
Inspect the oil cooler.
10. Fill the engine with clean engine oil.
11. Fill and bleed the engine cooling system. For additional information, refer to Cooling System
&/or Engine Block Heater.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Diagrams
Oil Filter: Diagrams
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Oil Filter Adapter
Oil Filter Adapter: Service and Repair Oil Filter Adapter
Oil Filter Adapter
Removal
Block Heater.
3. Disconnect the 2 coolant hoses from the oil cooler.
6. Remove and discard the oil filter.
7. Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
Installation
1. Using a new gasket, install the oil filter adapter and the 4 bolts.
2. NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
Install a new oil filter.
- Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter
adapter.
Install the EOP switch. -
4. Connect the EOP switch electrical connector.
5. Connect the 2 coolant hoses to the oil cooler.

6. Top off the engine with clean engine oil.
7. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Service and Repair > Oil Filter Adapter > Page 1359
Oil Filter Adapter: Service and Repair Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View
Oil Pan: Service and Repair Engine Lubrication Components - Exploded View
Transaxle Bolts For Oil Pan Removal - Exploded View
Transaxle Bolts for Oil Pan Removal
Oil Pan, Oil Pump Screen and Pickup Tube - Exploded View

Information > Service and Repair > Engine Lubrication Components - Exploded View > Page 1364
Oil Pan: Service and Repair Oil Pan
Oil Pan
Removal
3. NOTICE: To prevent damage to the transmission, do not loosen the transmission-to-engine bolts
more than 5 mm (0.19 in).
Loosen the upper bellhousing-to-engine bolt and stud bolt 5 mm (0.19 in).
4. Remove the oil level indicator and tube. For additional information, refer to Oil Level Indicator
and Tube See: Engine Oil Dip Stick - Dip Stick
Tube/Service and Repair/Oil Level Indicator and Tube.
5. Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
6. Loosen the RH engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
7. Remove the 2 bellhousing-to-oil pan bolts.
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Slide the transaxle rearward 5 mm (0.19 in).
11. Drain the engine oil.
- Install the drain plug.
12. Remove the 4 engine front cover-to-oil pan bolts.
13. Remove the 13 bolts and the oil pan.
Installation
cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces
of sealant.
Clean and inspect all mating surfaces.
2. NOTE: If the oil pan is not secured within 10 minutes of sealant application, the sealant must be
removed and the sealing area cleaned with metal
surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer.
Failure to follow this procedure can cause future oil leakage.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to
the oil pan-to-engine front cover mating surface.
3. Position the oil pan onto the engine and install the 13 oil pan bolts finger-tight.
4. NOTE: The engine front cover-to-oil pan bolts must be tightened first to align the front surface of
the oil pan flush with the front surface of the
engine block.
Install the 4 engine front cover-to-oil pan bolts.
5. Tighten the oil pan bolts in the sequence shown.

7. Alternate tightening the 1 LH bellhousing-to-engine and 1 RH engine-to-bellhousing lower bolts

to slide the transaxle and engine together.
8. Tighten the remaining LH bellhousing-to-engine bolt and the remaining rear

engine-to-bellhousing stud bolt.
9. Install the 2 bellhousing-to-oil pan bolts.
10. Install the 2 oil pan-to-bellhousing bolts.
11. Install the oil level indicator and tube. For additional information, refer to Oil Level Indicator and
Tube See: Engine Oil Dip Stick - Dip Stick
Tube/Service and Repair/Oil Level Indicator and Tube.
12. Tighten the top bellhousing-to-engine bolt and stud bolt.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP)
Switch

Component Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP)
Switch > Page 1375

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Service and Repair > Engine Lubrication Components - Exploded View
Oil Pick Up/Strainer: Service and Repair Engine Lubrication Components - Exploded View

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube
Oil Pump Screen and Pickup Tube
Removal
2. Remove the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and
Repair/Oil Pan.
3. Remove the 2 bolts and the oil pump screen and pickup tube.
Installation
1. Clean and inspect all mating surfaces.
2. Using a new gasket, install the oil pump screen and pickup tube and the 2 bolts.
3. Install the oil pan. For additional information, refer to Oil Pan See: Oil Pan/Service and Repair/Oil
Pan.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil pressure (hot @ 2,000 rpm)............................................................................................................

..............................................200-268 kPa (29-39 psi)
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 1385
Engine Oil Pressure: Testing and Inspection
Engine
Oil Pressure Test
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine.
2. Connect the Oil Pressure Gauge to the oil pressure switch oil galley port.
3. Run the engine until normal operating temperature is reached.
4. Run the engine at the specified rpm and record the gauge reading.
5. The oil pressure should be within specifications; refer to the specification chart in the appropriate
engine system.
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

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch,
Engine > Component Information > Description and Operation

Typical EOT Sensor

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Install the 5 intake manifold mounting bolts. Tighten all 7 bolts to.......................................................
............................................................................................................................18 Nm (159 lb-in).
Install the lower intake manifold bolt. Tighten to...................................................................................

.................................................................................................................18 Nm (159 lb-in).
Intake Manifold: Service and Repair
Intake Manifold
Intake Manifold (View 1 of 3)


Removal
1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle
2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to Fuel Delivery
and Air Induction.
and Tube See: Engine Lubrication/Engine Oil Dip
Stick - Dip Stick Tube/Service and Repair/Oil Level Indicator and Tube.
4. Remove the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
5. Remove the transaxle fluid indicator.
6. Remove the intake manifold lower bolt.

7. Detach the engine wiring harness pin-type retainer from the intake manifold.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire
harness retainer from the starter stud bolt.
9. Disconnect the electronic throttle control electrical connector.
10. Disconnect the fuel vapor return hose.
11. Disconnect the power brake booster vacuum tube.
- Depress the quick release locking ring.
- Pull the vacuum tube out of the quick release fitting.
12. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
13. Detach the wiring harness retainer from the intake manifold and disconnect the Knock Sensor
(KS) electrical connector.
14. Detach the 4 wiring harness pin-type retainers from the intake manifold.
15. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash
bracket to the intake manifold. The 2 bolts are
equipped with an attachment feature that allows them to be loosened but remain attached to the
intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
Loosen the 2 intake manifold bolts.
16. Remove the 5 intake manifold bolts.

17. Remove the EGR tube from the cylinder head.
18. Disconnect the PCV hose and remove the intake manifold.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including
valve or piston damage, check the
intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to
follow these instructions can result in engine damage.
Inspect and install new intake manifold gaskets if necessary.
2. Position the intake manifold and connect the PCV hose.
3. Install the EGR tube.
4. Attach the wiring harness retainer to the intake manifold and connect the KS electrical
connector.
5. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash
bracket to the intake manifold. The 2 bolts are
equipped with an attachment feature that allows them to be loosened but remain attached to the
intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
Install the intake manifold and hand-tighten the 2 intake manifold bolts.
6. Install the 5 intake manifold mounting bolts.
- Tighten all 7 bolts to 18 Nm (159 lb-in).
7. Attach the 4 wiring harness pin-type retainers to the intake manifold.
8. Connect the MAP sensor electrical connector.
9. Connect the power brake booster vacuum tube.
- Push the vacuum tube into the quick release fitting.

10. Connect the fuel vapor return hose.
11. Connect the electronic throttle control electrical connector.
12. Connect the EOP switch electrical connector and attach the wire harness retainer to the starter
stud bolt.
13. Attach the engine wiring harness pin-type retainer to the intake manifold.
14. Install the lower intake manifold bolt.
15. Install the transaxle fluid indicator.
16. Install the fuel rail. For additional information, refer to Fuel Delivery and Air Induction.
Tube See: Engine Lubrication/Engine Oil Dip
18. Install the Air Cleaner (ACL) and outlet pipe. For additional information, refer to Fuel Delivery
and Air Induction.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Exploded View - Flexplate and Crankshaft Rear Seal With Retainer
Plate
Crankshaft Main Bearing Seal: Service and Repair Exploded View - Flexplate and Crankshaft Rear
Seal With Retainer Plate
Flexplate and Crankshaft Rear Seal With Retainer Plate

Plate > Page 1403
Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Seal with Retainer Plate
Crankshaft Rear Seal with Retainer Plate
Removal
2. Remove the flexplate. For additional information, refer to Flexplate See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Removal and
Replacement/Flexplate.
3. Drain the engine oil.
- Install the drain plug and tighten to 28 Nm (21 lb-ft).
and Tube See: Engine Lubrication/Engine Oil Dip
5. NOTICE: If the oil pan is not removed damage to the rear oil seal retainer joint can occur.
Remove the 17 bolts and the oil pan.
6. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
Installation
1. Using the Crankshaft Rear Main Oil Seal Installer, position the crankshaft rear oil seal with
retainer plate onto the crankshaft.
2. Install the crankshaft rear seal with retainer plate and 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).

Plate > Page 1404
cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces
of sealant.
Clean and inspect all the oil pan, cylinder block and front cover flange mating surfaces.
4. NOTICE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use
silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to
follow this procedure can cause future oil leakage.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the
silicone gasket and sealant.
Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the oil pan.
- Install the oil pan and the 2 bolts finger-tight.
5. Install the 4 engine front cover-to-oil pan bolts.
6. Install the remaining oil pan bolts.
- Tighten in the sequence shown to 25 Nm (18 lb-ft).
Tube See: Engine Lubrication/Engine Oil Dip
8. Install the flexplate. For additional information, refer to Flexplate See: Transmission and
Drivetrain/Flex Plate/Service and Repair/Removal and
Replacement/Flexplate.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair > Crankshaft Pulley and Crankshaft Front Seal - Exploded View
Front Crankshaft Seal: Service and Repair Crankshaft Pulley and Crankshaft Front Seal - Exploded
View
Crankshaft Pulley and Crankshaft Front Seal

Component Information > Service and Repair > Crankshaft Pulley and Crankshaft Front Seal - Exploded View > Page 1409
Front Crankshaft Seal: Service and Repair Crankshaft Front Seal
Crankshaft Front Seal
Removal
1. Remove the crankshaft pulley. For additional information, refer to Lower End Components -
Exploded View See: Service and Repair/Removal
and Replacement/Lower End Components - Exploded View and Crankshaft Pulley See: Cylinder
Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Crankshaft Pulley.
2. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
Installation
1. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
Component Information > Service and Repair > Crankshaft Pulley and Crankshaft Front Seal - Exploded View > Page 1410
2. Install the crankshaft pulley. For additional information, refer to Lower End Components -
Exploded View See: Service and Repair/Removal and
Replacement/Lower End Components - Exploded View and Crankshaft Pulley See: Cylinder Block
Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Crankshaft Pulley.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair > Valve Train Components - Exploded View
Valve Guide Seal: Service and Repair Valve Train Components - Exploded View

Component Information > Service and Repair > Valve Train Components - Exploded View > Page 1415
Valve Guide Seal: Service and Repair Valve Seals
Valve Seals
Removal
2. Remove the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters
and Push Rods/Camshaft/Service and
Repair/Removal and Replacement/Camshafts.
original positions.
4. Remove the spark plugs. For additional information, refer to Ignition System.
5. NOTICE: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed
air from the cylinder until the valve spring,
valve spring retainer and valve collet is installed. Any loss of air pressure will allow the valve to fall
into the cylinder.
Connect the compressed air supply to the No. 1 cylinder.
6. NOTE: Place all parts in order to one side.
Apply compressed air to the cylinder and remove the valve spring.
- Using the Valve Spring Compressors, compress the valve spring and remove the valve collet,
using some multi-purpose grease and a small screwdriver.
- Remove the valve spring retainer and the valve spring.
7. Using the Valve Stem Oil Seal Remover and Slide Hammer, remove and discard the valve seal.
Installation
1. Install the valve stem seal installation sleeve.
2. Using the Valve Stem Oil Seal Installer, install the valve seal.
3. NOTE: Check the seating of the valve collet.
Using the Valve Spring Compressors, install the valve spring.
- Insert the valve spring and the valve spring retainer.
- Compress the valve spring and install the valve collet using some multi-purpose grease and a
small screwdriver.
4. Disconnect the compressed air supply.
5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to Ignition System.
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to Camshafts See: Camshaft, Lifters and
Push Rods/Camshaft/Service and Repair/Removal
and Replacement/Camshafts.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP)
Switch

> Component Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP)
Switch > Page 1426

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Description and Operation

Typical EOT Sensor

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Camshaft Gear/Sprocket: Specifications
Tighten to..............................................................................................................................................
.........................................................72 Nm (53 lb-ft).
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Timing Chain: Diagrams
Timing Chain Alignment
Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.
Install the timing chain.
NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent
engine rotation can result in engine damage.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Timing Chain Tensioner: Specifications
Install the timing chain tensioner and the 2 bolts. Tighten to................................................................
......................................................................................................................................10 Nm (89
lb-in).
Timing Chain Tensioner: Service and Repair
Timing Drive Components
Removal
2. Remove the engine front cover. For additional information, refer to Engine Front Cover See:
Timing Cover/Service and Repair.
3. Compress the timing chain tensioner in the following sequence.
1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by
pushing the timing chain arm toward the tensioner.
3. Insert a paper clip into the hole to retain the tensioner.
4. Remove the 2 bolts and the timing chain tensioner.
5. Remove the RH timing chain guide.
6. Remove the timing chain.

7. Remove the bolts and the LH timing chain guide.
8. NOTICE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to
the tool or the camshaft can occur.
NOTE: Intake camshaft drive gear shown, exhaust camshaft drive gear similar.
Remove the bolts and the camshaft drive gears.
- Use the flats on the camshaft to prevent camshaft rotation.
Installation
1. Install the camshaft drive gears and the bolts. Do not tighten the bolts at this time.
2. Install the LH timing chain guide and bolts.
3. Install the timing chain.

4. Install the RH timing chain guide.
NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the
compressed position, follow the next 4 steps.
5. NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.
6. Using a small pick, push back and hold the ratchet mechanism.
7. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
8. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the
plunger in during installation.
9. Install the timing chain tensioner and the 2 bolts.

- Remove the paper clip to release the piston.
damage.
11. Install the front cover. For additional information, refer to Engine Front Cover See: Timing
Cover/Service and Repair.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Timing Cover: Specifications
Install the engine front cover. Tighten the bolts in the sequence shown, to the following
specifications: Tighten the 8-mm bolts to.............................................................................................
................................................................................10 Nm (89 lb-in). Tighten the 13-mm bolts to.......
..............................................................................................................................................................
.......48 Nm (35 lb-ft).
Timing Cover: Service and Repair

Engine Front Cover
Removal
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley See:
Cylinder Block Assembly/Harmonic Balancer -
Crankshaft Pulley/Service and Repair/Crankshaft Pulley.
- Detach the 2 wiring harness retainers from the engine front cover.
5. Remove the 2 bolts and the CKP sensor.
6. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
7. Remove the 3 bolts and the coolant pump pulley.
8. Remove the coolant degas bottle. For additional information, refer to Cooling System &/or Engine
Block Heater.
9. Remove the power steering pump. For additional information, refer to Steering.
10. Remove the engine mount. For additional information, refer to Engine Mount See: Drive Belts,
Mounts, Brackets and Accessories/Engine
Mount/Service and Repair/Removal and Replacement.
11. Slightly raise the engine for access to the accessory drive idler pulley.
12. Remove the accessory drive idler pulley. For additional information, refer to Drive Belts,
Mounts, Brackets and Accessories.
13. Remove the bolts and the engine front cover.
Installation
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive
means to clean sealing surfaces. These tools
cause scratches and gouges which make leak paths.
Clean and inspect the mounting surfaces of the engine and the front cover.
2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of
applying the silicone gasket and sealant.
Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint
areas. Apply a 2.5 mm (0.10 in) bead of silicone gasket and sealant to the front cover.
3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following
specifications:
- Tighten the 8-mm bolts to 10 Nm (89 lb-in).
- Tighten the 13-mm bolts to 48 Nm (35 lb-ft).

4. Install the accessory drive idler pulley. For additional information, refer to Drive Belts, Mounts,
5. Lower the engine to the installed position.
6. Install the engine mount. For additional information, refer to Engine Mount See: Drive Belts,
Mounts, Brackets and Accessories/Engine
Mount/Service and Repair/Removal and Replacement.
7. Install the power steering pump. For additional information, refer to Steering.
8. Install the coolant degas bottle. For additional information, refer to Cooling System &/or Engine
Block Heater.
9. Install the coolant pump pulley and the 3 bolts.
- Do not tighten at this time.
10. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
NOTE: Lubricate the oil seal with clean engine oil.
Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
11. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley See: Cylinder
Block Assembly/Harmonic Balancer -
Crankshaft Pulley/Service and Repair/Crankshaft Pulley.
cover.
13. Install the CKP sensor and the 2 bolts.
- Do not tighten the bolts at this time.

- Tighten the 2 bolts to 7 Nm (62 lb-in).
- Attach the 2 wiring harness retainers to the engine front cover.
17. Tighten the coolant pump pulley bolts.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation
Overview
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Page 1456
VCT System
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications
Fuel Pressure
pressure........................................................................393-413 kPa (57-60 psi)
Pressure > System Information > Specifications > Page 1461
personal injury.
and Repair.
Pressure > System Information > Specifications > Page 1462
pressure release.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Diagrams

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order..........................................................................................................................................
.........................................................................1-3-4-2
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Gap
Spark Plug Gap....................................................................................................................................

....................................1.25-1.35 mm (0.049-0.053 in)
Plug > Component Information > Specifications > Gap > Page 1478
Spark Plugs..........................................................................................................................................
........................................................12 Nm 106 (lb-in)
Plug > Component Information > Specifications > Page 1479
Spark Plug............................................................................................................................................
...............................................................AGSF32YPC
carbon fouling.
-



Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View

Plug > Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1484
Spark Plugs
Powertrain Management/Ignition
System/Ignition Coil/Service and Repair/Ignition Coil-On-Plug.
the spark plugs.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check > System Information > System Diagnosis > Compression Test
Engine
Compression Test

Compression Check > System Information > System Diagnosis > Compression Test > Page 1490
Compression Check > System Information > System Diagnosis > Compression Test > Page 1491
Engine
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Adjustments
intake: 0.25 mm (0.0095 in).
- exhaust: 0.30 mm (0.0115 in).
intake: 0.22-0.28 mm (0.008-0.011 in).
- exhaust: 0.27-0.33 mm (0.010-0.013 in).
location.
Components - Exploded View See: Camshaft, Lifters and Push Rods/Camshaft/Service and
Repair/Removal and Replacement/Valve Train Components - Exploded View and Valve Tappets
See: Camshaft, Lifters and Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and
Replacement/Valve Tappets.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
Water Pump: Specifications
Coolant Pump Tighten to......................................................................................................................

.................................................................................10 Nm (89 lb-in)
> Page 1498
Water Pump: Service and Repair
Coolant Pump
and Bleeding See: Cooling System/Service and
4. Remove the 3 coolant pump pulley bolts and the pulley.

5. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing
and tightening the fasteners, or damage to
the coolant pump may occur.
Remove the 3 coolant pump bolts and the coolant pump.
6. NOTE: Install a new coolant pump O-ring seal and lubricate with clean engine coolant.

> Page 1499
Filling and Bleeding See: Cooling
System/Service and Repair/Cooling System Draining, Filling and Bleeding.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity:
..............................................................................................................................................................
..................................................... 6.1 qts (5.7 Liters)
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 1505
Coolant: Fluid Type Specifications
Engine Coolant
Ford Part Name - Motorcraft Specialty Orange Engine Coolant with bittering agent
Ford Part Number - VC-3-B (US) - CVC-3-B (Canada)
Ford Specification - WSS-M97B44-D
NOTE: Add the coolant type originally equipped in your vehicle.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Service and Repair
Coolant Reservoir: Service and Repair
Degas Bottle
1. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew
the coolant pressure relief cap when the
engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these
instructions may result in serious personal injury.
Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn
counterclockwise. When the pressure is released, remove the pressure relief cap.
2. Using hose clamp pliers, clamp the lower degas bottle hose.
3. Using a suction device, siphon the coolant from the degas bottle.
4. Disconnect the degas bottle-to-radiator hose.
5. Disconnect the degas bottle-to-coolant outlet hose.
6. Disconnect the lower degas bottle hose-to-radiator.
7. Remove the degas bottle bolt.
8. Release the degas bottle mounting bracket tab on the rear of the degas bottle and remove the
degas bottle.
10. Fill the degas bottle. Refer to Cooling System Draining, Filling and Bleeding See: Service and
Repair/Cooling System Draining, Filling and
Bleeding for the recommended coolant mixture and fill level.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Locations > Engine Cooling Fan Motor 1
Radiator Cooling Fan Motor: Locations Engine Cooling Fan Motor 1
Motor > Component Information > Locations > Engine Cooling Fan Motor 1 > Page 1514
Radiator Cooling Fan Motor: Locations Engine Cooling Fan Motor 2
Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1517
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Radiator Cooling Fan Motor: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Radiator Cooling Fan Motor: Connector Views
Engine Cooling Fan Motor 1
Engine Cooling Fan Motor 2

Motor > Component Information > Diagrams > Page 1538
Radiator Cooling Fan Motor: Description and Operation
Fan Control
The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C
on/off status, A/C pressure) to determine engine cooling fan needs.
For variable speed electric fan(s):
The PCM controls the fan speed and operation using a duty cycle output on the fan control variable
(FCV) circuit. The fan controller (located at or integral to the engine cooling fan assembly) receives
the FCV command and operates the cooling fan at the speed requested (by varying the power
applied to the fan motor).
EDGE/MKX, FLEX, MKS, MKT, TAURUS, FUSION/MILAN/MKZ, CROWN VICTORIA/GRAND

MARQUIS, TOWN CAR: FCV DUTY CYCLE OUTPUT FROM PCM (negative duty cycle)
For relay controlled fans:
The PCM controls the fan operation through the fan control (FC), (single speed fan applications),
low fan control (LFC) and high fan control (HFC) outputs. Some applications have the xFC circuit
wired to 2 separate relays.
For 2-speed fans, although the PCM output circuits are called low and high fan control, cooling fan
speed is controlled by a combination of these outputs. Refer to the following tables.
2.0L Focus And Transit Connect (With A/C): PCM FC Output State For Cooling Fan Speeds
2.5L Escape: PCM FC Output State For Cooling Fan Speeds

Motor > Component Information > Diagrams > Page 1539
Radiator Cooling Fan Motor: Service and Repair
Cooling Fan Motor and Shroud
2. Disconnect the cooling fan motor and shroud resistor electrical connector.
3. Disconnect the RH and LH cooling fan motor electrical connector.
- Detach the LH cooling fan motor wiring harness pin-type retainer.

4. Remove the 2 nuts and the cooling fan motor and shroud.

Motor Relay > Component Information > Locations > Low Speed Fan Control Relay
Motor Relay > Component Information > Locations > Low Speed Fan Control Relay > Page 1544
Motor Relay > Component Information > Testing and Inspection > Relays - Micro
Motor Relay > Component Information > Testing and Inspection > Relays - Micro > Page 1547
Resistor > Component Information > Diagrams
Radiator Cooling Fan Resistor: Diagrams
Resistor > Component Information > Diagrams > Page 1553
Speed Sensor > Component Information > Description and Operation

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

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Fan Clutch: Tools and Equipment
Fan Clutch Holding Tool AST tool# 8005
Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan.
2009 Suggested user price: $41.20
Assenmacher Specialty Tools 1 800 525 2943

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder
Head Temperature (CHT) Sensor
Software
Typical CHT Sensor

> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder
Head Temperature (CHT) Sensor > Page 1566


> Engine Temperature Sensor > Component Information > Locations
> Engine Temperature Sensor > Component Information > Locations > Page 1570
> Engine Temperature Sensor > Component Information > Locations > Page 1571
> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature (CHT)
Sensor
Software
Typical CHT Sensor

> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature (CHT)
Sensor > Page 1574
Sensor


> Engine Temperature Sensor > Component Information > Description and Operation > Page 1575
connector.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Service and Repair
Fan Shroud: Service and Repair
Cooling Fan Motor and Shroud
2. Disconnect the cooling fan motor and shroud resistor electrical connector.
3. Disconnect the RH and LH cooling fan motor electrical connector.
- Detach the LH cooling fan motor wiring harness pin-type retainer.

4. Remove the 2 nuts and the cooling fan motor and shroud.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair
Heater Core: Service and Repair
Heater Core
Service and Repair > Page 1582
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
2. Drain the engine coolant. For additional information, refer to Cooling System &/or Engine Block
Heater.
4. Remove the RH lower instrument panel insulator.
5. Remove the screw and the floor duct.
6. Release the 2 heater hose clamps and disconnect the heater hoses from the heater core.
7. Remove the 6 in-vehicle crossbeam bracket bolts and remove the brackets (RH shown).
8. Remove the LH floor duct clip between the heater core and evaporator core housing and the
dash panel.
9. Remove the LH floor duct.
1. Remove the LH floor duct clip
2. Remove the LH floor duct screw.
- Remove the LH floor duct.
10. Remove the RH floor duct.
1. Remove the RH floor duct clip.
2. Remove the RH floor duct screw.
- Remove the RH floor duct.
11. Remove the heater core cover.
1. Remove the 2 heater core cover screws.
2. Remove the 2 heater core cover clips.
3. Release the heater core cover tab and remove the heater core cover and heater core as an
assembly.
12. Remove the heater core tube bracket screw.
13. Remove the heater core.
15. Fill the engine coolant level. For additional information, refer to Cooling System &/or Engine
Block Heater.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair
Radiator: Service and Repair
Radiator
and Bleeding See: Service and Repair/Cooling
System Draining, Filling and Bleeding.
2. Remove the 2 bolts, pin-type retainer and the LH front splash shield.
3. Disconnect the upper radiator and degas bottle hoses from the radiator.
4. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor
and Shroud See: Radiator Cooling
Fan/Radiator Cooling Fan Motor/Service and Repair.
5. Remove the 2 cooling fan and shroud bolts from the radiator.
6. NOTE: The 2 side lower air deflectors may become detached when positioning the lower air
deflector aside.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service
and Repair > Page 1588
Remove the 4 pin-type retainers and position the lower air deflector aside.
7. Disconnect the lower radiator hose from the radiator.
8. Remove the A/C tube bracket nut from the RH side of the lower radiator support.
- To install, tighten 9 Nm (80 lb-in).
9. Position a jackstand below the lower radiator support to support the cooling module.
10. NOTE: The cooling module will have to be lifted upward to remove the lower radiator support
and then positioned back onto the jackstand.
Remove the 4 bolts and the lower radiator support.
- To install, tighten 25 Nm (18 lb-ft).
11. Slide the radiator towards the LH side of vehicle to separate the radiator from the A/C
condenser core and remove the radiator.
Filling and Bleeding See: Service and

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations > Low Speed Fan Control Relay
Radiator Cooling Fan Motor Relay > Component Information > Locations > Low Speed Fan Control Relay > Page 1594
Radiator Cooling Fan Motor Relay > Component Information > Testing and Inspection > Relays - Micro
Radiator Cooling Fan Motor Relay > Component Information > Testing and Inspection > Relays - Micro > Page 1597
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Radiator Cooling Fan Speed Sensor > Component Information > Description and Operation

Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Software
Typical CHT Sensor

Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component


Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
1613
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Locations > Page
1614
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Software
Typical CHT Sensor

Sensor


connector.

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Thermostat Housing: Service and Repair
Thermostat Housing
NOTE: The thermostat and thermostat housing are serviced as an assembly.
2. Remove the power steering pump. For additional information, refer to Steering.
3. Disconnect the Knock Sensor (KS) electrical connector.

- Detach the KS electrical connector pin-type retainer.
4. Disconnect the heater hose at the thermostat housing.
5. Disconnect the lower radiator hose at the thermostat housing.
6. Remove the 3 bolts and the thermostat housing.
- Remove and discard the thermostat housing seal.
- To install, tighten the bolts to 10 Nm (89 lb-in).
7. NOTE: Lubricate the thermostat housing seal with clean engine coolant.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Service and Repair > Page 1622

Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications
Water Pump: Specifications
Coolant Pump Tighten to......................................................................................................................

.................................................................................10 Nm (89 lb-in)
Water Pump: Service and Repair
Coolant Pump
4. Remove the 3 coolant pump pulley bolts and the pulley.

5. NOTICE: Make sure the coolant pump is correctly seated to the engine block before installing
and tightening the fasteners, or damage to
the coolant pump may occur.
Remove the 3 coolant pump bolts and the coolant pump.
6. NOTE: Install a new coolant pump O-ring seal and lubricate with clean engine coolant.


Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation
Catalytic Converter: Description and Operation

CATALYST AND EXHAUST SYSTEMS
Overview
The catalytic converter and exhaust systems work together to control the release of harmful engine
exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N),
carbon dioxide (CO2) and water (H2O). However, it also contains carbon monoxide (CO), oxides of
nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants
of CO, NOx, and HCs, and their emission into the atmosphere must be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the
powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the
description for the Catalyst Efficiency Monitor. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness
Codes/Catalyst Efficiency Monitor
Only two HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the
catalyst are used for primary fuel control while the sensors after the catalyst (HO2S12/HO2S22)
are used to monitor catalyst efficiency.
Typical V-Engine
> Description and Operation > Page 1632
Typical In-Line Engine
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The
concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst, they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C
(475°F to 575°F). A fast light catalyst is a three way catalytic converter (TWC) that is located as
close to the exhaust manifold as possible. Because the light off catalyst is located close to the
exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located
under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion
efficiency for that catalyst.
Three Way Catalytic Converter (TWC) Conversion Efficiency

A TWC requires a stoichiometric air/fuel ratio, 14.7 pounds of air to 1 pound of gasoline (14.7:1),
for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be
tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly
decrease the conversion efficiency. For example a rich mixture decreases the HC and CO
conversion efficiency while a lean mixture decreases the NOx conversion efficiency.
For vehicles using E85 the required air/fuel ratio is 9.8:1. Other gasoline/ethanol mixtures require a
variable air/fuel ratio between 14.7:1 to 9.8:1 dependent on the percentage of ethanol content.
TWC Conversion Efficiency Chart
Exhaust System
The exhaust system conveys engine emissions from the exhaust manifold to the atmosphere.
Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter
through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst.
The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust
emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic
converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler.
Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
> Description and Operation > Page 1633
Typical Bank 1 Catalyst 2 HO2S Configuration
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line
with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming
a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific
vehicle, refer to the Exhaust System for the exhaust system exploded view.
Three Way Catalytic (TWC) Converter
The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The
TWC catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of
NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio
at or close to stoichiometry.
Exhaust Manifold Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
The HO2Ss provide the powertrain control module (PCM) with information related to the oxygen
content of the exhaust gas. For additional information on the HO2S, refer to Engine Control
Components. See: Powertrain Management/Computers and Control Systems/Description and
Operation/Engine Control Components
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
> Service and Repair > Catalytic Converter
Catalytic Converter: Service and Repair Catalytic Converter
Catalytic Converter
NOTICE: The exhaust hanger isolators are constructed from a special material. Use only the
correct specification exhaust hanger isolators or damage to the exhaust system may occur.
NOTICE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration
of the rubber.
NOTICE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator
to separate from the exhaust hanger bracket during vehicle operation.
NOTE: Check the exhaust hanger isolators for damage and fatigue. Install new exhaust hanger
isolators as required.
NOTE: The exhaust system has 2 catalytic converters: a catalytic converter mounted to the
exhaust manifold and an underbody catalytic converter that is serviced with the muffler and tailpipe.
To service the underbody catalytic converter, refer to the Muffler and Tailpipe See: Muffler/Service
and Repair/Muffler and Tailpipe procedure.
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
- Detach the wiring retainer.
3. Remove the 2 upper catalytic converter heat shield bolts.
4. Remove the muffler and tailpipe. For additional information, refer to Muffler and Tailpipe See:
Muffler/Service and Repair/Muffler and Tailpipe.
6. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these
instructions may cause damage to the exhaust
flexible pipe.
Support the exhaust flexible pipe with a support wrap or suitable splint.
> Service and Repair > Catalytic Converter > Page 1636
7. Remove the 2 lower bolts and position aside the catalytic converter heat shield.
8. Remove the 2 bolts and the steering gear heat shield.
9. Remove the engine support bracket-to-catalytic converter bolt.
10. Remove the 2 engine support bracket-to-engine block bolts.
- Remove the engine support bracket.
11. Detach the 2 catalytic converter exhaust hanger isolators.
12. Remove and discard the 2 exhaust manifold-to-catalytic converter nuts.
- Remove the catalytic converter.
- Install new gaskets and nuts.

Catalytic Converter: Service and Repair Exhaust System - Exploded View
Exhaust System - Exploded View

Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Install the 7 new exhaust manifold studs. Tighten to............................................................................

........................................................................................................................17 Nm (150 lb-in).
Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence
shown in 2 stages: Stage 1: Tighten to................................................................................................
.........................................................................................48 Nm (35 lb-ft). Stage 1: Tighten to...........
..............................................................................................................................................................
................48 Nm (35 lb-ft).
Install the exhaust manifold heat shield and the 4 bolts. Tighten to.....................................................
.................................................................................................................................................10 Nm
(89 lb-in).
Service and Repair > Procedures
Exhaust Manifold: Procedures
Exhaust Manifold Cleaning and Inspection
1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the
gasket sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an
exhaust manifold is serviced.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm
(0.0002 in) per running foot of length, such as Snap-On(R) GA438A or equivalent. For example, if
the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in)
from end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for
warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
Service and Repair > Procedures > Page 1644
Exhaust Manifold: Removal and Replacement
Exhaust Manifold
Removal
2. Remove the catalytic converter. For additional information, refer to Exhaust System &/or
Catalytic Converter.
3. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
4. Remove the 4 exhaust manifold heat shield bolts and the heat shield.
5. Remove and discard the 7 exhaust manifold nuts.
6. Remove the exhaust manifold and discard the exhaust manifold gasket.
7. Remove and discard the 7 exhaust manifold studs.
8. Clean and inspect the exhaust manifold. For additional information, refer to Engine.
Installation
1. Install the 7 new exhaust manifold studs.
2. NOTICE: Failure to tighten the catalytic converter nuts to specification before installing the
converter bracket bolts will cause the
converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter nuts to specification a second time will cause the
converter to develop an exhaust leak.
Service and Repair > Procedures > Page 1645
Install a new exhaust manifold gasket, the exhaust manifold and 7 new nuts in the sequence
shown in 2 stages:
3. Install the exhaust manifold heat shield and the 4 bolts.
4. Connect the HO2S electrical connector.
- Attach the wiring retainer.
5. Install the catalytic converter. For additional information, refer to Exhaust System &/or Catalytic
Converter.
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Service and Repair > Exhaust Flexible Pipe
Exhaust Pipe: Service and Repair Exhaust Flexible Pipe
Exhaust Flexible Pipe
Removal
NOTE: The production catalytic converter and exhaust flexible pipe assembly is a one-piece
construction. For service, the exhaust flexible pipe is a separate component and requires cutting
the production catalytic connector.
1. Remove the catalytic converter, refer to the Catalytic Converter See: Catalytic Converter/Service
and Repair/Catalytic Converter procedure.
2. NOTE: It is necessary to cut the production catalytic converter to enable the service exhaust
flexible pipe section to be installed. Before cutting
any part of the exhaust system, check that the position of the cut is correct in comparison to the
service section being installed.
Cut the pipe as indicated in the illustration.
Installation
1. NOTE: Make sure that the exhaust flexible pipe locating cutout is aligned with the locating dowel
on the catalytic converter.
Install the exhaust flexible pipe on the catalytic converter and tighten the service clamp.
2. Install the catalytic converter, refer to the Catalytic Converter See: Catalytic Converter/Service
and Repair/Catalytic Converter procedure.
Service and Repair > Exhaust Flexible Pipe > Page 1650
Exhaust Pipe: Service and Repair Exhaust System - Exploded View

Service and Repair > Exhaust Flexible Pipe > Page 1651
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
and Repair > Exhaust System - Exploded View
Muffler: Service and Repair Exhaust System - Exploded View

and Repair > Exhaust System - Exploded View > Page 1656
Muffler: Service and Repair Muffler and Tailpipe
Muffler and Tailpipe
Removal
of the rubber.
NOTE: If replacement is not required, the production underbody catalytic converter and muffler and
tailpipe assembly can be removed and installed as one piece. It is only necessary to cut the
production exhaust to enable the service section(s) to be fitted. Before cutting any part of the
exhaust system, check that the position of the cut is correct in comparison to the service section(s)
being installed.
2. NOTE: It is necessary to lubricate the catalytic converter-to-muffler and tailpipe nuts and studs
with penetrating and lock lubricant to assist in
removal.
Remove the 2 catalytic converter-to-muffler and tailpipe nuts.
- Discard the nuts and gasket.
3. Detach the 3 exhaust hanger isolators and remove the muffler and tailpipe assembly.
4. Make the appropriate cut(s) to the muffler and tailpipe assembly to service the underbody
catalytic converter, muffler or tailpipe.
- Cut the muffler and tailpipe as indicated in the illustration.
Installation
NOTE: Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
1. NOTE: Do not tighten the service clamp at this time.
Install the service clamp(s).
2. Position the muffler and tailpipe assembly and attach the 3 exhaust hanger isolators.
3. Install a new gasket and 2 new catalytic converter-to-muffler and tailpipe nuts.
4. Align the muffler and tailpipe assembly and tighten the service clamp(s).

Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Page 1665

Removal
mode DTC is:
mechanisms.
Installation

Modules - Computers and Control Systems > Electronic Throttle Control Module > Component Information > Description
and Operation
Overview
information on the APP sensor, refer to Engine Control Components. See: Computers and Control
Systems/Description and Operation/Engine Control Components


Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations
Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 1681
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Procedures
Description
reset.
completed.
misfire DTCs.
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Procedures > Page 1692
Removal
(PATS).
Bus.
Installation


Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and
Inspection > Relays - Micro
Inspection > Relays - Micro > Page 1698
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Relays -
Micro
Micro > Page 1707
Micro > Page 1708
Micro > Page 1709
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and
Modules - Ignition System > Ignition Relay > Component Information > Locations
Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Relays - Micro
Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Relays - Micro > Page
1724
1725
1726
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Page 1732

Page 1733
2-Track APP Sensor
Electronic Throttle Control (ETC). See: Computers and Control Systems/Electronic Throttle Control
Module/Description and Operation
3-Track APP Sensor

Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations


(TCC) scheduling.
Typical MAF Sensor



Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and
Operation
follows: -
Typical BPP Switch

strategy.
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page
1752
1753
1754

1755

Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation

information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy. See: Computers
and Control Systems/Description and Operation/Powertrain Control Software
Typical CHT Sensor



Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
1767
1768
1769
Typical CKP Sensor

1770
Removal
1771
sensor.
Installation
1772

Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
1776
1777
information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy. See: Computers
and Control Systems/Description and Operation/Powertrain Control Software
Typical CHT Sensor

Sensor


connector.

Tank and Filler Pipe - Exploded View

Fuel Pump Module
personal injury.
1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Fuel Delivery and Air
Induction/Fuel Tank/Service and Repair/Removal
and Replacement/Fuel Tank.
ring.
arm.

Fuel Level Sender
personal injury.
See: Fuel Delivery and Air Induction/Fuel
Pump/Service and Repair/Fuel Pump Module.

Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
1795
1796
1797

Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
1801

1802

sensor.
efficiency.

1803

Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Page 1814
Page 1815
Page 1816

Typical MAP Sensor

Switches - Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description
and Operation

Typical EOT Sensor

Sensor(HO2S) #11
Sensor(HO2S) #11 > Page 1824
Sensor (HO2S) #12

Sensor (HO2S) #12 > Page 1827

Typical HO2S
Heated Oxygen Sensor (HO2S) > Page 1830
accuracy.
Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Exploded View
removal.

retainer.
removal.


Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations >
Page 1839

Operation > Power Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

Operation > Power Steering Pressure (PSP) Switch > Page 1842
Sensor
parking maneuvers.
Typical PSP Sensor



Description and Operation > Page 1847

Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
Throttle Control (ETC). See: Computers and Control Systems/Electronic Throttle Control
Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page 1852
Typical TP Sensor
Locations
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
> Output Shaft Speed (OSS) Sensor
generated.
> Output Shaft Speed (OSS) Sensor > Page 1865
Typical VSS
and Operation


Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Page 1875

Page 1876
2-Track APP Sensor
3-Track APP Sensor

Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations


(TCC) scheduling.
Typical MAF Sensor



Operation > Fuel Rail Pressure (FRP) Sensor

Operation > Fuel Rail Pressure (FRP) Sensor > Page 1888
Sensor
Typical FRPT Sensor

Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and
Operation
Typical FRPT Sensor

Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Typical IFS Switch


> Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
> Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page 1903
Typical TP Sensor
Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations


Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Typical CKP Sensor

Removal
sensor.
Installation

> Removal and Replacement

Assembly

Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Fuel Pressure
pressure........................................................................393-413 kPa (57-60 psi)
personal injury.
and Repair.
pressure release.
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Diagrams

Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair

Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Firing Order..........................................................................................................................................
.........................................................................1-3-4-2
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Gap
Spark Plug Gap....................................................................................................................................

....................................1.25-1.35 mm (0.049-0.053 in)
Component Information > Specifications > Gap > Page 1957
Spark Plugs..........................................................................................................................................
........................................................12 Nm 106 (lb-in)
Spark Plug............................................................................................................................................
...............................................................AGSF32YPC
carbon fouling.
-



Component Information > Service and Repair > Engine Ignition Components - Exploded View

Component Information > Service and Repair > Engine Ignition Components - Exploded View > Page 1963
Spark Plugs
Ignition System/Ignition Coil/Service and
Repair/Ignition Coil-On-Plug.
the spark plugs.

Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
System Information > System Diagnosis > Compression Test
Engine
Compression Test

System Information > System Diagnosis > Compression Test > Page 1969
System Information > System Diagnosis > Compression Test > Page 1970
Engine
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Adjustments
1. Remove the valve cover. For additional information, refer to Valve Cover See: Engine, Cooling
and Exhaust/Engine/Service and Repair/Removal
and Replacement/Valve Cover.
intake: 0.25 mm (0.0095 in).
- exhaust: 0.30 mm (0.0115 in).
intake: 0.22-0.28 mm (0.008-0.011 in).
- exhaust: 0.27-0.33 mm (0.010-0.013 in).
location.
Components - Exploded View See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and
Push Rods/Camshaft/Service and Repair/Removal and Replacement/Valve Train Components -
Exploded View and Valve Tappets See: Engine, Cooling and Exhaust/Engine/Camshaft, Lifters and
Push Rods/Lifter / Lash Adjuster/Service and Repair/Removal and Replacement/Valve Tappets.
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor

2-Track APP Sensor
Electronic Throttle Control (ETC). See: Electronic Throttle Control Module/Description and
Operation
3-Track APP Sensor

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >


(TCC) scheduling.
Typical MAF Sensor



Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >


sensor.
efficiency.


Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >

Removal
mode DTC is:
mechanisms.
Installation

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure
Switch > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Brake Pressure
Switch > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page 2011
strategy.
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >


Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature (CHT)
Sensor
information, refer to Powertrain Control Software for Fail-Safe Cooling Strategy. See: Description
and Operation/Powertrain Control Software
Typical CHT Sensor

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Description and Operation > Cylinder Head Temperature (CHT)
Sensor > Page 2026


Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Typical CKP Sensor

Removal
sensor.
Installation

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Data Link Connector: Locations
Data Link Connector: Diagrams
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator >
Electronic Throttle Actuator: Locations
Electronic Throttle Actuator: Diagrams
Electronic Throttle Actuator: Description and Operation
Electronic Throttle Actuator Control (TAC)

The electronic TAC is a DC motor controlled by the PCM. There are 2 designs for the TAC, parallel
and in-line. The parallel design has the motor under the bore parallel to the plate shaft. The motor
housing is integrated into the main housing. The in-line design has a separate motor housing. An
internal spring is used in both designs to return the throttle plate to a default position. The default
position is typically a throttle angle of 7 to 8 degrees from the hard stop angle. The closed throttle
plate hard stop is used to prevent the throttle from binding in the bore. This hard stop setting is not
adjustable and is set to result in less airflow than the minimum engine airflow required at idle. For
additional information, refer to Torque Based Electronic Throttle Control (ETC). See: Electronic
Typical In-Line TAC Design
Typical Parallel TAC Design

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Module
Overview
information on the APP sensor, refer to Engine Control Components. See: Description and
> Component Information > Description and Operation > Page 2050



Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Description
reset.
completed.
misfire DTCs.
Removal
(PATS).
Bus.
Installation


Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > Cylinder Head Temperature (CHT) Sensor
Typical CHT Sensor

Component Information > Description and Operation > Cylinder Head Temperature (CHT) Sensor > Page 2075
Sensor


connector.

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View

Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page 2081
Fuel Pump Module
personal injury.
ring.
arm.

Fuel Level Sender
personal injury.

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator -
Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
Idle Air Control (IAC) Valve
NOTE: The IAC valve assembly is not adjustable and cannot be cleaned.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control: -
no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
Information > Diagrams > Diagram Information and Instructions > Page 2100
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Information Bus: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Information Bus: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
14-1
14-2
Diagrams: Other diagrams referred to by number (i.e. 13-2, 24-6, 10-2, etc.) within these diagrams
can be found at Diagrams By Number. See: Diagrams/Electrical Diagrams/Diagrams By Number
Locations: Location Views (reference numbers starting with 151-) referred to within these diagrams
can be found at Location Views. See: Locations/Component Locations
Information Bus: Description and Operation
Communications Network
Multiplexing is a method of sending 2 or more signals simultaneously over a single circuit.
Multiplexing is used to allow 2 or more electronic modules (nodes) to communicate simultaneously
over a twisted-wire pair [data (+) and data (-)] network. The information or messages that can be
communicated on these wires consists of commands, status or data. The advantage of using
multiplexing is to reduce the weight of the vehicle by reducing the number of redundant
components and electrical wiring.
The vehicle has 3 module communication networks which are connected to the Data Link
Connector (DLC), located under the driver side of the instrument panel:
- High Speed Controller Area Network (HS-CAN)
- Medium Speed Controller Area Network (MS-CAN)
- ISO
Network Topology
Network Termination And Gateway Function
The Controller Area Network (CAN) uses 120 ohm resistors across the data (+) and data (-) at
each end of the network main circuit branch, or "backbone", to improve communication reliability.
The termination resistors are located inside modules referred to as "termination modules". The ISO
network does not use termination resistors.
Communication Network Impedance

Network termination improves bus message reliability by:
- stabilizing bus voltage.
- eliminating electrical interference.
The Instrument Cluster (IC) is the gateway module, translating messages on the HS-CAN to the
MS-CAN and vice versa. This function allows a message to be distributed throughout both
networks.
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Information Bus: Initial Inspection and Diagnostic Overview
Special Tool(s) Used With Diagnostics
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of electrical damage.
- If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step.
Visual Inspection Chart
3. NOTE: Make sure to use the latest scan tool software release.
Connect the scan tool to the DLC.

Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2125
- NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
from the DLC are provided to the VCM.
If the Integrated Diagnostic System (IDS) does not communicate with the VCM:
- Check the VCM connection to the vehicle.
- Check the scan tool connection to the VCM.
- GO to Pinpoint Test O, to diagnose No Power To The Scan Tool. See: Pinpoint Tests/Pinpoint
Test O: No Power To The Scan Tool
4. Establish a scan tool session.
- NOTE: The scan tool first attempts to communicate with the PCM, after establishing
communication with the PCM, the scan tool then attempts to communicate with all other modules
on the vehicle.
If an IDS session cannot be established with the vehicle, (IDS may state "No communication can
be established with the PCM"):
- Choose "NO" when the scan tool prompts whether or not to retry communication.
- Enter either a PCM part number, tear tag or calibration number to identify the vehicle and start a
session (the PCM part number and 4-character tear tag are printed on the PCM label).
- GO to Pinpoint Test A, to diagnose The PCM Does Not Respond To The Scan Tool. See:
Pinpoint Tests/Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
5. Carry out the network test.
- If the network test passes, retrieve and record the continuous memory DTCs and proceed to Step
6.
- If the network test fails, GO to Symptom Chart to diagnose the failed communication network.
See: Symptom Related Diagnostic Procedures
- If a module fails to communicate during the network test, GO to Symptom Chart. See: Symptom
6. Retrieve and review the DTCs.
- If the DTCs retrieved are related to the concern, go to DTC Charts. Follow the non-network DTC
diagnostics (B-codes, C-codes, P-codes) prior to the network DTC diagnostics (U-codes). For all
other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Body Control Systems. See:
Diagnostic Trouble Code Descriptions/Module Communications Network See: Body and
Frame/Body Control Systems/Testing and Inspection
- If no DTCs related to the concern are retrieved, GO to Symptom Chart. See: Symptom Related
Diagnostic Procedures
Principles Of Operation
Principles of Operation
Vehicle communication utilizes both ISO and Controller Area Network (CAN) communications.
Both the High Speed Controller Area Network (HS-CAN) and the Medium Speed Controller Area
Network (MS-CAN) use an unshielded twisted-pair cable of data (+) and data (-) circuits. The
HS-CAN operates at a maximum data transfer speed of 500 Kbps and is designed for applications
in which modules must respond as rapidly as required by the driver or needed by the process being
controlled. The MS-CAN operates at a maximum data transfer speed of 125 Kbps for bus
messages and is designed for general information transfer.
The ISO communications network is a single wire network. The ISO communications network does
not permit intermodule communication and is for diagnostic use only.
Controller Area Network (CAN) Fault Tolerance
NOTE: The oscilloscope traces below are from the Integrated Diagnostic System (IDS)
oscilloscope taken using the IDS pre-configured CAN settings. The traces are for both data (+) and
data (-) taken simultaneously (2-channel) at a sample rate of 1 mega-sample per second (1MS/s)
or greater. Traces below are viewed at 500mV per division (vertical axis) and 20 microseconds
(20µs) per division (horizontal axis). Readings taken with a different oscilloscope vary from those
shown. Compare any suspect readings to a known good vehicle.
Normal CAN Operation

The data (+) and data (-) circuits are each regulated to approximately 2.5 volts during neutral or
rested network traffic. As messages are sent on the data (+) circuit, voltage is increased by
approximately 1.0 volt. Inversely, the data (-) circuit is reduced by approximately 1.0 volt when a
message is sent.
Successful communication of a message can usually be identified by the slight spike at the end of
a message transmission. Any signals that are significantly different than the normal CAN waveform
may cause network DTCs (U-codes) to set or may cause a complete network outage.
CAN Circuits Shorted Together
In the event that the data (+) and data (-) circuits become shorted together, the signal stays at base
voltage (2.5V) continuously and all communication capabilities are lost.
CAN (+) Circuit Shorted To Ground

In the event that the data (+) circuit becomes shorted to ground, both the data (+) and data (-)
circuits are pulled low (0V) and all communication capabilities are lost.
CAN (-) Circuit Shorted To Ground
In the event that the data (-) circuit becomes shorted to ground, the data (-) circuit is pulled low (0V)
and the data (+) circuit reaches near-normal peak voltage (3.0V) during communication but falls to
0V instead of normal base voltage (2.5V). Communication may continue but at a degraded level.
CAN (+) Circuit Shorted To Battery Voltage

In the event that the data (+) circuit becomes shorted to battery voltage, the data (+) circuit is pulled
high (12V) and the data (-) circuit falls to abnormally high voltage (above 5V) during communication
and reaches battery voltage (12V) for peak voltage. Communication may continue but at a
degraded level.
CAN (-) Circuit Shorted To Battery Voltage
In the event that the data (-) circuit becomes shorted to battery voltage, both the data (+) and data
(-) circuits are pulled high (12V) and all communication capabilities are lost.
CAN Circuit Signal Corruption

Rhythmic oscillations, inductive spikes or random interference can corrupt the network
communications. The corruption signal source may be outside electrical interference such as
motors or solenoids or internal interference generated from a module on the network. In some
cases, an open in either the data (+) or data (-) circuit to a network module may cause the module
to emit interference on the one circuit which is still connected. The trace shown is an example of a
"sawtooth" pattern transmitted from a module with one open network circuit.
Other corruptions may be present when a module is intermittently powered up and down. The
module on power up may initiate communication out of sync with other modules on the network
causing momentary communication outages.
Controller Area Network (CAN) Multiplex Messages
Modules on the CAN utilize simultaneous communication of 2 or more messages on the same
network circuits. The following chart summarizes the messages sent and received on the network.
CAN Module Communication Message Chart
NOTE: This chart describes the specific HS-CAN and MS-CAN messages broadcast by each
module, and the module(s) that receive the message.
Module Configuration
This system provides step-by-step module configuration procedures. Carry out Programmable
Module Installation (PMI) when another diagnostic/repair information directs to carry out
configuration or when DTCs from the list below are present: See: Programming and Relearning
Configurable modules accommodate a variety of vehicle options, eliminating the need for many
unique modules for one vehicle line. These modules must be configured when replaced as part of a
repair procedure. Configurable modules should not be exchanged between vehicles since the
settings are unique to each vehicle. Failure to configure a new module may result in incorrect
operation and/or DTCs setting.
The following are the 3 different methods of configuration:
- Programmable Module Installation (PMI)
- Module reprogramming ("flashing")
- Programmable parameters
Some modules do not support all 3 methods.
Definition of Terms
The following are definitions of configuration terms:
Programmable Module Installation (PMI)
PMI is a scan tool process which configures settings in a new module. Data used for the PMI
process is automatically downloaded from the original module and stored when a scan tool session
is started. If this data cannot be retrieved from the module being replaced, the scan tool may
prompt for As-Built data entry or display a list of parameter values that need to be manually
selected. Some modules are reprogrammed during PMI when a strategy/calibration update is
available. To carry out PMI, refer to Programmable Module Installation (PMI) See: Programming
and Relearning.
NOTE: It is important that the scan tool identifies the vehicle and obtains configuration data prior to
removing any modules. The new module must be able to communicate with the scan tool in order
to carry out PMI. See: Programming and Relearning
Module Reprogramming
Module reprogramming (also referred to as "flashing") is a scan tool process which updates the
strategy/calibration in a module. Reprogramming a module with the same level of software will not
improve module operation or repair a hardware failure. Module reprogramming is automatically
carried out during PMI when a later strategy/calibration is available.
NOTE: Module reprogramming should be limited to circumstances where a published TSB

procedure recommends doing so.
NOTE: A module cannot communicate with other modules on the communication network while
being reprogrammed. Clear any network communication DTCs which may have been set in other
modules during the reprogramming process.
Programmable Parameters
Programmable parameters are customer preference items that may be modified by the dealer via
the scan tool or in some cases, modified by the customer following a procedure listed in the
Owner's Literature. While many configuration options may exist for a module, only a few of these
options are
programmable parameters.
Adaptive Learning and Calibration
Some modules require a separate learning procedure be carried out if replaced as part of a repair
procedure. For adaptive learning and calibration instructions, refer to the specific module removal
and installation procedures.
Vehicle Identification (VID) Block
Some PCMs contain a memory area called a Vehicle Identification (VID) block. The PCM VID block
commonly stores powertrain configuration items such as Vehicle Identification Number (VIN), tire
size, axle ratio, and whether or not the vehicle is equipped with cruise control.
Module Address
A unique module address is assigned to each module on the network for identification.
As-Built Data
As-Built data is a VIN-specific module configuration record. During vehicle build, the configuration
from all modules is downloaded and stored in the As-Built database. As-Built data does not reflect
customer preference items that have been changed from the default state. These items need to be
changed using programmable parameters after the module is configured.
NOTE: It is not necessary to obtain As-Built data unless directed to do so by the scan tool. This
data may be accessed from the technician service publication website.
Module Configuration and Parameter Chart
Information Bus: Diagnostic Trouble Code Descriptions
Module Communications Network
DTC Charts
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged
wiring or low battery voltage occurrences. Additionally, vehicle repair procedures such as module
reprogramming often set network DTCs. Replacing a module to resolve a network DTC is unlikely
to resolve the concern. To prevent repeat network DTC concerns, inspect all network wiring,
especially connectors. Test the vehicle battery, refer to Battery.
Communication Network DTC Chart
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure-type code. The
failure-type code provides information about specific fault conditions such as opens, or shorts to
ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist
in determining DTC history.
DTC Chart
NOTE: Some modules on this vehicle utilize a 5-character DTC followed by a 2-character
failure-type code. The failure-type code provides information about specific fault conditions such as
opens, or shorts to ground. Continuous Memory DTCs have an additional 2-character DTC status
code suffix to assist in determining DTC history.
Information Bus: Symptom Related Diagnostic Procedures
Symptom Chart
Information Bus: Pinpoint Tests
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 14, Module Communications Network for schematic and connector
information. See: Diagrams/Electrical Diagrams/Diagrams By Number
Refer to Wiring Diagram Set 23, Electronic Engine Controls for schematic and connector
Normal Operation
The PCM communicates with the scan tool through the High Speed Controller Area Network
(HS-CAN).
This pinpoint test is intended to diagnose the following:
- Wiring, terminals or connectors
- PCM
PINPOINT TEST A: THE PCM DOES NOT RESPOND TO THE SCAN TOOL
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings.
Refer to Battery.
------------------------------------------------- A1 VERIFY WHETHER OTHER HS-CAN MODULES PASS

THE NETWORK TEST
- Enter the following diagnostic mode on the scan tool: Network Test.
- In the LH pane of the IDS network test display screen, verify whether any HS-CAN modules
passed the network test.
Is the text "pass" or a DTC listed next to any of the following modules (if equipped): ABS module,
Instrument Cluster (IC), PCM or Steering Angle Sensor Module (SASM)?
Yes
If "pass" or a DTC was listed next to the PCM, a network fault is not currently present. GO to
Pinpoint Test M to diagnose an intermittent HS-CAN fault condition. See: Pinpoint Test M: No High
Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding
If "pass" or a DTC was listed next to one or more modules other than the PCM, GO to A2.
No
No modules are currently communicating on the HS-CAN. GO to Pinpoint Test L to diagnose no
HS-CAN communication. See: Pinpoint Test L: Intermittent No Medium Speed Controller Area
Network (MS-CAN) Communication, One Or More Modules Are Not Respo
------------------------------------------------- A2 VERIFY THE COMPUTERS AND CONTROL SYSTEMS

INFORMATION PINPOINT TEST QA HAS BEEN CARRIED OUT
- Verify that Computers and Control Systems Information pinpoint test QA has been carried out.
- Has pinpoint test QA been carried out?
Yes
GO to A3.
No
REFER to Computers and Control Systems Information, Pinpoint Tests, pinpoint test QA to
diagnose no communication with the PCM.
------------------------------------------------- A3 CHECK THE HS-CAN TERMINATION RESISTANCE
- Ignition OFF.
- Disconnect: Negative Battery Cable.
- Measure the resistance between the DLC C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT),
harness side and the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness side.
- Is the resistance between 54 and 66 ohms?
Yes
CONNECT the negative battery cable. GO to A5.
No
GO to A4.
------------------------------------------------- A4 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM

AND THE DLC FOR AN OPEN
- Disconnect: PCM C175b.
- Measure the resistance between the PCM C175b-59, circuit 4-EC7 (GY/RD), harness side and
the DLC C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness side.
- Measure the resistance between the PCM C175b-43, circuit 5-EC7 (BU/RD), harness side and
the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness side.
- Are the resistances less than 5 ohms?
Yes
CONNECT the negative battery cable. GO to A5.
No
REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT
the network test with the scan tool.
------------------------------------------------- A5 CHECK FOR CORRECT PCM OPERATION
- Disconnect all the PCM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the PCM connectors and make sure they seat correctly.
- Operate the system and verify the concern is still present.
Is the concern still present?
Yes
INSTALL a new PCM. REFER to Computers and Control Systems. CLEAR the DTCs. REPEAT the
network test with the scan tool.
No
The system is operating correctly at this time. The concern may have been caused by a loose or
corroded connector.
-------------------------------------------------
Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test B: The ABS Module Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 42, Vehicle Dynamic Systems for schematic and connector
Normal Operation
The ABS module communicates with the scan tool through the High Speed Controller Area
Network (HS-CAN).

- Fuse
- ABS module
PINPOINT TEST B: THE ABS MODULE DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
-------------------------------------------------
B1 CHECK THE ABS MODULE VOLTAGE SUPPLY CIRCUITS FOR AN OPEN
- Ignition OFF.
- Disconnect: ABS Module C135 (Without Stability Control) or C155 (With Stability Control).
- Ignition ON.
- For vehicles without stability control, measure the voltage between the ABS module C135-1,
circuit 30-CF6 (RD), harness side and ground; and between the ABS module C135-20, circuit
15-CF6 (GN/YE), harness side and ground.
- For vehicles with stability control, measure the voltage between the ABS module C155-8, circuit
15-CF6 (GN/YE), harness side and ground; and between the ABS module C155-32, circuit 30-CF6
(RD), harness side and ground.
- Is the voltage greater than 10 volts?
Yes
GO to B2.
No
VERIFY Battery Junction Box (BJB) fuse 15 (20A) or Central Junction Box (CJB) fuse 161 (7.5A) is
OK. If OK, REPAIR the circuit in question. If not OK, REFER to the Wiring Diagrams to identify the
possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool.
See: Diagrams/Electrical Diagrams/Diagrams By Number
------------------------------------------------- B2 CHECK THE ABS MODULE GROUND CIRCUIT FOR AN

OPEN
- Ignition OFF.
- For vehicles without stability control, measure the resistance between the ABS module C135-26,
circuit 91-CF13 (BK/BU), harness side and ground.
- For vehicles with stability control, measure the resistance between the ABS module C155-16,
circuit 91-CF6 (BK/YE), harness side and ground.
Yes
For vehicles without stability control, GO to B3.
For vehicles with stability control, GO to B4.
No
REPAIR the circuit. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- B3 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS

MODULE AND THE DLC FOR AN OPEN - WITHOUT STABILITY CONTROL
- Measure the resistance between the ABS module C135-23, circuit 4-EC7 (GY/RD), harness side
and the Data Link Connector (DLC) C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness side.
- Measure the resistance between the ABS module C135-21, circuit 5-EC7 (BU/RD), harness side
and the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness side.
Yes
CONNECT the negative battery cable. GO to B5.
No
------------------------------------------------- B4 CHECK THE HS-CAN CIRCUITS BETWEEN THE ABS

MODULE AND THE DLC FOR AN OPEN - WITH STABILITY CONTROL
- Measure the resistance between the ABS module C155-12, circuit 4-EC7 (GY/RD), harness side
and the Data Link Connector (DLC) C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness side.
- Measure the resistance between the ABS module C155-13, circuit 5-EC7 (BU/RD), harness side
and the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness side.
Yes
CONNECT the negative battery cable. GO to B5.
No
------------------------------------------------- B5 CHECK FOR CORRECT ABS MODULE OPERATION
- Disconnect the ABS module connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the ABS module connector and make sure it seats correctly.
- Is the concern still present?
Yes
INSTALL a new ABS module. REFER to Antilock Brakes / Traction Control Systems. CLEAR the
DTCs. REPEAT the network test with the scan tool.
No
corroded connector.
-------------------------------------------------
Pinpoint Test C: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test C: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 60, Instrument Cluster for schematic and connector information. See:
Diagrams/Electrical Diagrams/Diagrams By Number
Normal Operation
The Instrument Cluster (IC) communicates with the scan tool and other network modules on the
High Speed Controller Area Network (HS-CAN). The IC communicates with other network modules
on the Medium Speed Controller Area Network (MS-CAN).
- Fuse(s)
- IC
PINPOINT TEST C: THE IC DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
------------------------------------------------- C1 CHECK THE HS-CAN TERMINATION RESISTANCE
- Ignition OFF.
- Disconnect the scan tool cable from the Data Link Connector (DLC).
Yes
GO to C3.
No
GO to C2.
------------------------------------------------- C2 CHECK THE HS-CAN CIRCUITS BETWEEN THE DLC

AND THE IC FOR AN OPEN
- Disconnect: IC C220b.
harness side and the IC C220b-23, circuit 4-EC8 (GY/VT), harness side.
- Measure the resistance between the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH),
harness side and the IC C220b-24, circuit 5-EC8 (BU/WH), harness side.
Yes
CONNECT the negative battery cable. GO to C7.
No
------------------------------------------------- C3 CHECK THE MS-CAN TERMINATION RESISTANCE
- Measure the resistance between the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13
(GY/VT)/4-EC14 (GY/OG), harness side and the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK), harness side.
Yes
GO to C5.
No
GO to C4.
------------------------------------------------- C4 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC

(GY/VT)/4-EC14 (GY/OG), harness side and the IC C220b-21, circuit 4-EC13 (GY/VT), harness
side.
- Measure the resistance between the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK), harness side and the IC C220b-22, circuit 5-EC13 (BU/WH), harness
side.
Are the resistances less than 5 ohms?
Yes
No
------------------------------------------------- C5 CHECK THE IC GROUND CIRCUIT FOR AN OPEN
- Measure the resistance between the IC C220b-2, circuit 91-GC14 (BK/OG) harness side and
ground.
- Is the resistance less than 5 ohms?
Yes
No
REPAIR the circuit. CONNECT the negative battery cable. CLEAR the DTCs. REPEAT the network
test with the scan tool.
------------------------------------------------- C6 CHECK THE IC VOLTAGE SUPPLY CIRCUITS FOR AN

OPEN
- Ignition ON.
- Measure the voltage between the IC C220b-1, circuit 29-GG14 (OG), harness side and ground;
and between the IC C220b-6, circuit 15-GG14 (GN/RD), harness side and ground.
- Are the voltages greater than 10 volts?
Yes
GO to C7.
No
VERIFY Central Junction Box (CJB) fuse 148 (7.5A) or fuse 179 (7.5A) is OK. If OK, REPAIR the
circuit in question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the
circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool. See:
------------------------------------------------- C7 CHECK FOR CORRECT IC OPERATION
- Disconnect the IC connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the IC connector and make sure it seats correctly.
Yes
INSTALL a new IC. REFER to Instrument Panel, Gauges and Warning Indicators. CLEAR the
No
corroded connector.
-------------------------------------------------
Pinpoint Test D: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Or No ISO
Communication
Pinpoint Tests
Pinpoint Test D: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool Or No ISO
Communication
Refer to Wiring Diagram Set 131, Parking Aid for schematic and connector information. See:
Normal Operation
The PAM communicates with the scan tool through the ISO communications network.
- Fuse
- PAM
PINPOINT TEST D: THE PAM DOES NOT RESPOND TO THE SCAN TOOL OR NO ISO
NETWORK COMMUNICATION
Refer to Battery.
------------------------------------------------- D1 CHECK THE PAM VOLTAGE SUPPLY CIRCUIT FOR

AN OPEN
- Ignition OFF.
- Disconnect: PAM C2023.
- Ignition ON.
- Measure the voltage between the PAM C2023-1, circuit 15-GN10 (GN/YE), harness side and
ground.
Yes
GO to D2.
No
VERIFY the Central Junction Box (CJB) fuse 152 (7.5A) is OK. If OK, REPAIR the circuit. CLEAR
the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- D2 CHECK THE PAM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Measure the resistance between the PAM C2023-3, circuit 91-GN10 (BK/YE), harness side and
ground.
Yes
CONNECT the negative battery cable. GO to D3.
No
------------------------------------------------- D3 CHECK THE ISO CIRCUIT FOR A SHORT TO

VOLTAGE
- Ignition ON.
- Measure the voltage between the DLC C251-7, circuit 8-EE13 (WH/RD), harness side and
ground.
- Is any voltage present?
Yes
No
GO to D4.
------------------------------------------------- D4 CHECK THE ISO CIRCUIT FOR A SHORT TO GROUND
- Ignition OFF.
- Measure the resistance between the DLC C251-7, circuit 8-EE13 (WH/RD), harness side and
ground.
- Is the resistance greater than 10,000 ohms?
Yes
GO to D5.
No
------------------------------------------------- D5 CHECK THE ISO CIRCUIT BETWEEN THE PAM AND

THE DLC FOR AN OPEN
- Measure the resistance between the PAM C2023-5, circuit 8-EE13 (WH/RD), harness side and
the DLC C251-7, circuit 8-EE13 (WH/RD), harness side.
Yes
GO to D6.
No
------------------------------------------------- D6 CHECK FOR CORRECT PAM OPERATION
- Disconnect the PAM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the PAM connector and make sure it seats correctly.
Yes
INSTALL a new PAM. REFER to Collision Avoidance and Parking Assist Systems. CLEAR the
No
corroded connector.
-------------------------------------------------
Pinpoint Test E: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test E: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 130, Audio System for schematic and connector information. See:
Normal Operation
The Audio Control Module (ACM) communicates with the scan tool through the Medium Speed
Controller Area Network (MS-CAN).
- Fuse
- ACM
PINPOINT TEST E: THE ACM DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
------------------------------------------------- E1 CHECK THE ACM VOLTAGE SUPPLY CIRCUITS FOR

AN OPEN
- Ignition OFF.
- Disconnect: ACM C240b.
- Ignition ON.
- Measure the voltage between the ACM C240b-15, circuit 29-MB15 (OG/BK), harness side and
ground.
Yes
GO to E2.
No
VERIFY the Central Junction Box (CJB) fuse 151 (15A) is OK. If OK, REPAIR the circuit in
question. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit
short. CLEAR the DTCs. REPEAT the network test with the scan tool. See: Diagrams/Electrical
Diagrams/Diagrams By Number
------------------------------------------------- E2 CHECK THE ACM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Measure the resistance between the ACM C240b-11, circuit 91-MD34 (BK/YE), harness side and
ground; and between the ACM C240b-12, circuit 91-MD15 (BK/GN), harness side and ground.
Yes
GO to E3.
No
------------------------------------------------- E3 CHECK THE MS-CAN CIRCUITS BETWEEN THE ACM

- Measure the resistance between the ACM C240b-9, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT),
harness side and the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14 (GY/OG),
harness side.
- Measure the resistance between the ACM C240b-10, circuit 5-EC1 (BU/RD)/5-EC13 (BU/WH),
harness side and the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13 (BU/WH)/5-EC14 (BU/BK),
harness side.
Yes
CONNECT the negative battery cable. GO to E4.
No
------------------------------------------------- E4 CHECK FOR CORRECT ACM OPERATION
- Disconnect all the ACM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the ACM connectors and make sure they seat correctly.
Yes
INSTALL a new ACM. REFER to Accessories and Optional Equipment. CLEAR the DTCs.
REPEAT the network test with the scan tool. TEST the system for normal operation.
No
corroded connector.
-------------------------------------------------
Pinpoint Test F: The Speech Recognition Module (SRM) Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test F: The Speech Recognition Module (SRM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 130, Audio System for schematic and connector information. See:
Normal Operation
The Speech Recognition Module (SRM) communicates with the scan tool through the Medium
Speed Controller Area Network (MS-CAN).
- Fuse
- SRM
PINPOINT TEST F: THE SRM DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
------------------------------------------------- F1 CHECK THE SRM VOLTAGE SUPPLY CIRCUIT FOR

AN OPEN
- Ignition OFF.
- Disconnect: SRM C2307.
- Measure the voltage between the SRM C2307-17, circuit 29-MC12 (OG/YE), harness side and
ground; and between the SRM C2307-18, circuit 29-MC12 (OG/YE), harness side and ground.
Yes
GO to F2.
No
VERIFY the Central Junction Box (CJB) fuse 151 (15A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool. See: Diagrams/Electrical Diagrams/Diagrams
By Number
------------------------------------------------- F2 CHECK THE SRM GROUND CIRCUIT FOR AN OPEN
- Measure the resistance between the SRM C2307-33, circuit 91-MC12 (BK/YE), harness side and
ground; and between the SRM C2307-34, circuit 91-MC12 (BK/YE), harness side and ground.
Yes
GO to F3.
No
------------------------------------------------- F3 CHECK THE MS-CAN CIRCUITS BETWEEN THE SRM

- Measure the resistance between the SRM C2307-14, circuit 4-EC1 (GY/RD), harness side and
the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14 (GY/OG), harness side.
- Measure the resistance between the SRM C2307-15, circuit 5-EC1 (BU/RD), harness side and
the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13 (BU/WH)/5-EC14 (BU/BK), harness side.
Yes
CONNECT the negative battery cable. GO to F4.
No
------------------------------------------------- F4 CHECK FOR CORRECT SRM OPERATION
- Disconnect the SRM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the SRM connector and make sure it seats correctly.
- Verify the concern is still present.
Yes
INSTALL a new SRM. REFER to Accessories and Optional Equipment. CLEAR the DTCs.
REPEAT the network test with the scan tool.
No
corroded connector.
-------------------------------------------------
Pinpoint Test G: The Occupant Classification System Module (OCSM) Does Not Respond To The
Scan Tool
Pinpoint Tests
Pinpoint Test G: The Occupant Classification System Module (OCSM) Does Not Respond To The
Scan Tool
Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector
Normal Operation
The Occupant Classification System Module (OCSM) communicates with the scan tool through the
Medium Speed Controller Area Network (MS-CAN).
- Fuse
- OCSM
PINPOINT TEST G: THE OCSM DOES NOT RESPOND TO THE SCAN TOOL
WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or
adaptive load limiting retractors. Failure to follow this instruction may result in the accidental
deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the
risk of serious personal injury or death.
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test. See: Initial Inspection and Diagnostic
Overview/Module Communications Network/Inspection and Verification
Refer to Battery.
------------------------------------------------- G1 CHECK THE OCSM VOLTAGE SUPPLY CIRCUIT FOR
AN OPEN
- Ignition OFF.
- Depower the SRS. Refer to Restraint Systems.
- Disconnect: OCSM C3159.
- Deactivate the SRS. Refer to Restraint Systems.
- Repower the SRS. Refer to Restraint Systems.
- Ignition ON.
- Measure the voltage between the OCSM C3159-1, circuit 14-JA60 (VT), harness side and
ground.
Yes
GO to G2.
No
VERIFY the Central Junction Box (CJB) fuse 162 (7.5A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. See:
REACTIVATE the SRS. REFER to Restraint Systems. CLEAR the DTCs. REPEAT the network
------------------------------------------------- G2 CHECK THE OCSM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Measure the resistance between the OCSM C3159-14, circuit 91-JA60 (BK/OG), harness side
and ground.
Yes
GO to G3.
No
REPAIR the circuit. REACTIVATE the SRS. CONNECT the negative battery cable. REFER to
Restraint Systems. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- G3 CHECK THE MS-CAN CIRCUITS BETWEEN THE

OCSM AND THE DLC FOR AN OPEN
- Measure the resistance between the OCSM C3159-18, circuit 4-JA60 (GY/VT), harness side and
- Measure the resistance between the OCSM C3159-9, circuit 5-JA60 (BU/WH), harness side and
Yes
CONNECT the negative battery cable. GO to G4.
No
REPAIR the circuit. REACTIVATE the SRS. CONNECT the negative battery cable. REFER to
Restraint Systems. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- G4 CHECK FOR CORRECT OCSM OPERATION
- Disconnect the OCSM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the OCSM connector and make sure it seats correctly.
Yes
INSTALL a new OCSM. REFER to Restraint Systems. REACTIVATE the SRS. CLEAR the DTCs.
No
corroded connector. REACTIVATE the SRS. REFER to Restraint Systems.
-------------------------------------------------
Pinpoint Test H: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test H: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 46, Supplemental Restraint System for schematic and connector
Normal Operation
The Restraints Control Module (RCM) communicates with the scan tool through the Medium Speed
Controller Area Network (MS-CAN).
- Fuse
- Case ground open
- RCM
PINPOINT TEST H: THE RCM DOES NOT RESPOND TO THE SCAN TOOL
WARNING: Never probe the electrical connectors on safety belt buckle/retractor pretensioners or
adaptive load limiting retractors. Failure to follow this instruction may result in the accidental
deployment of the safety belt pretensioners or adaptive load limiting retractors, which increases the
risk of serious personal injury or death.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy(R) or side air curtain
modules. Failure to follow this instruction may result in the accidental deployment of these
modules, which increases the risk of serious personal injury or death.
Refer to Battery.
------------------------------------------------- H1 CHECK THE RCM CONNECTION
- Ignition OFF.
- Depower the SRS. Refer to Restraint Systems.
- Disconnect: RCM C310a.
- Disconnect: RCM C310b.
- Inspect the RCM connector for damaged, pushed out or corroded pins.
Are RCM C310a pin 24 and RCM C310b pins 19 and 20 OK?
Yes
GO to H2.
No
REPAIR the RCM connector pins as necessary. CLEAR the DTCs. REPEAT the network test with
the scan tool.
------------------------------------------------- H2 CHECK THE RCM CASE GROUND

- Measure the resistance between the RCM case and a good chassis ground.
Yes
CONNECT the negative battery cable. GO to H3.
No
REPAIR the RCM case ground as necessary. CONNECT the negative battery cable. CLEAR the
------------------------------------------------- H3 CHECK THE RCM VOLTAGE SUPPLY CIRCUIT FOR

AN OPEN
- Repower the SRS. Refer to Restraint Systems.
- Ignition ON.
- Measure the voltage between the RCM C310a-24, circuit 15-JA10 (GN/OG), harness side and
ground.
Yes
GO to H4.
No
VERIFY the Central Junction Box (CJB) fuse 162 (7.5A) is OK. If OK, REPAIR the circuit.
REACTIVATE the SRS. REFER to Restraint Systems. If not OK, REFER to the Wiring Diagrams to
identify the possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with
the scan tool. See: Diagrams/Electrical Diagrams/Diagrams By Number
------------------------------------------------- H4 CHECK THE MS-CAN CIRCUITS BETWEEN THE RCM

- Measure the resistance between the RCM C310a-19, circuit 4-EC5 (GY/RD), harness side and
- Measure the resistance between the RCM C310a-20, circuit 5-EC5 (BU/RD), harness side and
Yes
CONNECT the negative battery cable. GO to H5.

No
------------------------------------------------- H5 CHECK FOR CORRECT RCM OPERATION
- Disconnect all the RCM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the RCM connectors and make sure they seat correctly.
Yes
INSTALL a new RCM. REFER to Restraint Systems. CLEAR the DTCs. REPEAT the network test
with the scan tool.
No
corroded connector.
-------------------------------------------------
Pinpoint Test I: The Tire Pressure Monitoring System (TPMS) Module Does Not Respond To The
Scan Tool
Pinpoint Tests
Pinpoint Test I: The Tire Pressure Monitoring System (TPMS) Module Does Not Respond To The
Scan Tool
Refer to Wiring Diagram Set 118, Tire Pressure Monitor System for schematic and connector
Normal Operation
The Tire Pressure Monitoring System (TPMS) module communicates with the scan tool through the
Medium Speed Controller Area Network (MS-CAN).
- Fuse
- TPMS module
PINPOINT TEST I: THE TPMS MODULE DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
------------------------------------------------- I1 CHECK THE TPMS MODULE VOLTAGE SUPPLY
CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: Tire Pressure Monitoring System (TPMS) Module C2409a.
- Ignition ON.
- Measure the voltage between the TPMS module C2409a-23, circuit 15-WA6 (GN/YE), harness
side and ground; and between the TPMS module C2409a-24, circuit 30-WA6 (RD), harness side
and ground.
Yes
GO to I2.
No
VERIFY the Central Junction Box (CJB) fuse 179 (7.5A) or the Battery Junction Box (BJB) fuse 19
(20A) is OK. If OK, REPAIR the circuit. If not OK, REFER to the Wiring Diagrams to identify the
possible causes of the circuit short. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- I2 CHECK THE TPMS MODULE GROUND CIRCUIT FOR

AN OPEN
- Ignition OFF.
- Measure the resistance between the TPMS module C2409a-13, circuit 31-WA1 (BK), harness
side and ground; and between the TPMS module C2409a-14, circuit 91-WA1 (BK/BU), harness
side and ground.
Yes
GO to I3.
No
-------------------------------------------------
I3 CHECK THE MS-CAN CIRCUITS BETWEEN THE TPMS MODULE AND THE DLC FOR AN
OPEN
- Disconnect: TPMS Module C2409b.
- Measure the resistance between the TPMS module C2409b-1, circuit 4-WA6 (GY), harness side
and the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14 (GY/OG), harness side.
- Measure the resistance between the TPMS module C2409b-2, circuit 5-WA6 (BU), harness side
and the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13 (BU/WH)/5-EC14 (BU/BK), harness side.
Yes
CONNECT the negative battery cable. GO to I4.
No
------------------------------------------------- I4 CHECK FOR CORRECT TPMS MODULE OPERATION

- Disconnect all the TPMS module connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the TPMS module connectors and make they seat correctly.
Yes
INSTALL a new TPMS module. REFER to Wheels and Tires. CLEAR the DTCs. REPEAT the
No
corroded connector.
-------------------------------------------------
Pinpoint Test J: The Generic Electronic Module (GEM) Does Not Respond To The Scan Tool
Pinpoint Tests
Pinpoint Test J: The Generic Electronic Module (GEM) Does Not Respond To The Scan Tool
Refer to Wiring Diagram Set 13, Power Distribution for schematic and connector information. See:
Normal Operation
The Generic Electronic Module (GEM) communicates with the scan tool through the Medium
Speed Controller Area Network (MS-CAN).
- Fuse
- GEM
PINPOINT TEST J: THE GEM DOES NOT RESPOND TO THE SCAN TOOL
Refer to Battery.
------------------------------------------------- J1 CHECK THE GEM VOLTAGE SUPPLY CIRCUIT FOR AN

OPEN
- Ignition OFF.
- Disconnect: Generic Electronic Module (GEM) C201a.

- Ignition ON.
- Measure the voltage between the GEM C201a-10, circuit 15-DK20 (GN/OG), harness side and
ground.
Yes
GO to J2.
No
VERIFY the Central Junction Box (CJB) fuse 179 (7.5A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. CLEAR the
DTCs. REPEAT the network test with the scan tool. See: Diagrams/Electrical Diagrams/Diagrams
By Number
------------------------------------------------- J2 CHECK THE GEM GROUND CIRCUIT FOR AN OPEN
- Ignition OFF.
- Disconnect: GEM C201d.
- Measure the resistance between the GEM C201d-2, circuit 91-DK20 (BK/RD), harness side and
ground.
Is the resistance less than 5 ohms?
Yes
GO to J3.
No
------------------------------------------------- J3 CHECK THE MS-CAN CIRCUITS BETWEEN THE GEM

- Disconnect: GEM C201b.
- Measure the resistance between the GEM C201b-23, circuit 4-EC14 (GY/OG), harness side and
- Measure the resistance between the GEM C201b-22, circuit 5-EC14 (BU/BK), harness side and

Yes
CONNECT the negative battery cable. GO to J4.
No
------------------------------------------------- J4 CHECK FOR CORRECT GEM OPERATION
- Disconnect all GEM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the GEM connectors and make sure they seat correctly.
Yes
INSTALL a new GEM. REFER to Body Control Systems. CLEAR the DTCs. REPEAT the network
No
corroded connector.
-------------------------------------------------
Pinpoint Test K: No Medium Speed Controller Area Network (MS-CAN) Communication, All
Modules Are Not Responding
Pinpoint Tests
Normal Operation
The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable,
circuits 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14 (GY/OG) and 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK). The Instrument Cluster (IC), while on the MS-CAN, communicates with
the scan tool only on the High Speed Controller Area Network (HS-CAN).
- Data Link Connector (DLC)
- Audio Control Module (ACM)
- Generic Electronic Module (GEM)
- IC
- Occupant Classification System Module (OCSM)
- Restraints Control Module (RCM)
- Speech Recognition Module (SRM) (if equipped)
- Tire Pressure Monitoring System (TPMS) module

PINPOINT TEST K: NO MS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic
Refer to Battery.
------------------------------------------------- K1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the Data Link Connector (DLC).
- Inspect DLC pins 3 and 11 for damage.
- Are DLC pins 3 and 11 OK?
Yes
GO to K2.
No
REPAIR the DLC as necessary. CLEAR the DTCs. REPEAT the network test with the scan tool.
------------------------------------------------- K2 CHECK THE MS-CAN TERMINATION RESISTANCE
Yes
GO to K3.
No
GO to K5.
------------------------------------------------- K3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS

FOR A SHORT TO GROUND
(GY/VT)/4-EC14 (GY/OG), harness side and ground; and between the DLC C251-11, circuit 5-EC1
(BU/RD)/5-EC13 (BU/WH)/5-EC14 (BU/BK), harness side and ground.
- Are the resistances greater than 1,000 ohms?
Yes
CONNECT the negative battery cable. GO to K4.
No
GO to K18.

FOR A SHORT TO VOLTAGE
- Ignition ON.
- Measure the voltage between the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14
(GY/OG), harness side and ground; and between the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK), harness side and ground.
Yes
No
The CAN has tested within specifications. GO to Pinpoint Test L to diagnose the intermittent
MS-CAN fault. See: Pinpoint Test L: Intermittent No Medium Speed Controller Area Network
(MS-CAN) Communication, One Or More Modules Are Not Respo
------------------------------------------------- K5 CHECK THE MS-CAN TERMINATION RESISTOR
Yes
GO to K6.
No
GO to K9.
------------------------------------------------- K6 CHECK THE MS-CAN TERMINATION RESISTOR WITH

THE GEM DISCONNECTED
Yes
GO to K7.
No
GO to K8.
------------------------------------------------- K7 CHECK THE MS-CAN CIRCUITS BETWEEN THE GEM

- Measure the resistance between the GEM C201b-23, circuit 4-EC14 (GY/OG), harness side and
- Measure the resistance between the GEM C201b-22, circuit 5-EC14 (BU/BK), harness side and
Yes
No
------------------------------------------------- K8 CHECK THE MS-CAN CIRCUITS BETWEEN THE DLC

(GY/VT)/4-EC14 (GY/OG), harness side and the IC C220b-21, circuit 4-EC13 (GY/VT), harness
side.
- Measure the resistance between the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK), harness side and the IC C220b-22, circuit 5-EC13 (BU/WH), harness
side.
Yes
No

FOR A SHORT TOGETHER
Yes
GO to K11.
No
GO to K10.
FOR AN OPEN
Yes
REPAIR the DLC or REPAIR the circuit in question. CONNECT all modules. CONNECT the
negative battery cable. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5
minutes. REPEAT the pinpoint test.
FOR A SHORT TOGETHER WITH THE GEM DISCONNECTED
- Disconnect: Generic Electronic Module (GEM) C201b.
Yes
GO to K12.
No
FOR A SHORT TOGETHER WITH THE RCM DISCONNECTED
- Disconnect: RCM C310a.
Yes
GO to K13.
No
FOR A SHORT TOGETHER WITH THE OCSM DISCONNECTED
Yes
GO to K14.
No
FOR A SHORT TOGETHER WITH THE TPMS MODULE DISCONNECTED
- Disconnect: Tire Pressure Monitoring System (TPMS) Module C2409b.
Yes
GO to K15.
No
FOR A SHORT TOGETHER WITH THE ACM DISCONNECTED

Yes
If the vehicle is equipped with a Speech Recognition Module (SRM), GO to K16.
If the vehicle is not equipped with an SRM, GO to K17.
No
FOR A SHORT TOGETHER WITH THE SRM DISCONNECTED
Yes
GO to K17.
No
FOR A SHORT TOGETHER WITH THE IC DISCONNECTED
Yes
REPAIR the circuit. CONNECT all modules. CONNECT the negative battery cable. CLEAR the
No
FOR A SHORT TO GROUND WITH THE GEM DISCONNECTED
- Disconnect: Generic Electronic Module (GEM) C201b.
Yes
No
GO to K19.
FOR A SHORT TO GROUND WITH THE RCM DISCONNECTED
- Disconnect: Restraints Control Module (RCM) C310a.
Yes
No
GO to K20.
FOR A SHORT TO GROUND WITH THE OCSM DISCONNECTED
- Disconnect: Occupant Classification System Module (OCSM) C3159.
Yes
No
GO to K21.
FOR A SHORT TO GROUND WITH THE TPMS MODULE DISCONNECTED
- Disconnect: Tire Pressure Monitoring System (TPMS) Module C2409b.
Yes
No
GO to K22.
FOR A SHORT TO GROUND WITH THE ACM DISCONNECTED
Yes
No
If the vehicle is equipped with a Speech Recognition Module (SRM), GO to K23.
If the vehicle is not equipped with an SRM, GO to K24.
FOR A SHORT TO GROUND WITH THE SRM DISCONNECTED
Yes
No
GO to K24.
FOR A SHORT TO GROUND WITH THE IC DISCONNECTED
Yes
No
------------------------------------------------- K25 CHECK FOR CORRECT GEM OPERATION
- Disconnect all the GEM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
Yes
INSTALL a new GEM. REFER to Body Control Systems. CONNECT all modules. CLEAR the
No
corroded connector. CONNECT all modules. CLEAR the DTCs. REPEAT the network test with the
scan tool.
------------------------------------------------- K26 CHECK FOR CORRECT RCM OPERATION
- Disconnect all the RCM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the RCM connectors and make sure they seat correctly.
Yes
INSTALL a new RCM. REFER to Restraint Systems. CONNECT all modules. CLEAR the DTCs.
No
scan tool.
------------------------------------------------- K27 CHECK FOR CORRECT OCSM OPERATION
- Disconnect the OCSM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the OCSM connector and make sure it seats correctly.
Yes
INSTALL a new OCSM. REFER to Restraint Systems. CONNECT all modules. CLEAR the DTCs.
No
scan tool.
------------------------------------------------- K28 CHECK FOR CORRECT TPMS MODULE OPERATION
- Disconnect all the TPMS module connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the TPMS module connectors and make sure they seat correctly.
Yes
INSTALL a new TPMS module. REFER to Wheels and Tires. CONNECT all modules. CLEAR the
No
scan tool.
------------------------------------------------- K29 CHECK FOR CORRECT ACM OPERATION
- Disconnect all the ACM connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the ACM connectors and make sure they seat correctly.
Yes
INSTALL a new ACM. REFER to Accessories and Optional Equipment. CONNECT all modules.
CLEAR the DTCs. REPEAT the network test with the scan tool.
No
scan tool.
------------------------------------------------- K30 CHECK FOR CORRECT SRM OPERATION
- Disconnect the SRM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the SRM connector and make sure it seats correctly.

Yes
INSTALL a new SRM. REFER to Accessories and Optional Equipment. CONNECT all modules.
CLEAR the DTCs. REPEAT the network test with the scan tool.
No
scan tool.
------------------------------------------------- K31 CHECK FOR CORRECT IC OPERATION
- Disconnect all the IC connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the IC connectors and make sure they seat correctly.
Yes
INSTALL a new IC. REFER to Instrument Panel, Gauges and Warning Indicators. CONNECT all
modules. CLEAR the DTCs. REPEAT the network test with the scan tool.
No
scan tool.
-------------------------------------------------
Pinpoint Test L: Intermittent No Medium Speed Controller Area Network (MS-CAN)

Communication, One Or More Modules Are Not Respo
Pinpoint Tests
Pinpoint Test L: Intermittent No Medium Speed Controller Area Network (MS-CAN)

Communication, One Or More Modules Are Not Responding During Network Test
Normal Operation
The Medium Speed Controller Area Network (MS-CAN) uses an unshielded twisted pair cable.
In the event that either the MS-CAN (+) or MS-CAN (-) circuit becomes open to a module on the
network, unreliable network communication to all modules on the network may result.
PINPOINT TEST L: INTERMITTENT NO MS-CAN COMMUNICATION, ONE OR MORE

MODULES ARE NOT RESPONDING DURING NETWORK TEST
NOTE: Various modules set network DTCs during this test procedure. Clear DTCs from all
modules after the diagnostic procedure is completed.
Refer to Battery.
------------------------------------------------- L1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Disconnect the scan tool cable from the DLC.
Yes
GO to L2.
No
------------------------------------------------- L2 CHECK THE MS-CAN TERMINATION RESISTANCE
Yes
GO to L3.
No
CONNECT the negative battery cable. GO to Pinpoint Test K. See: Pinpoint Test K: No Medium
Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding
------------------------------------------------- L3 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS

Yes
CONNECT the negative battery cable. GO to L4.
No
CONNECT the negative battery cable. GO to Pinpoint Test K. See: Pinpoint Test K: No Medium
Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding
------------------------------------------------- L4 CHECK THE MS-CAN (+) AND MS-CAN (-) CIRCUITS

- Ignition ON.
- Measure the voltage between the DLC C251-3, circuit 4-EC1 (GY/RD)/4-EC13 (GY/VT)/4-EC14
(GY/OG), harness side and ground; and between the DLC C251-11, circuit 5-EC1 (BU/RD)/5-EC13
(BU/WH)/5-EC14 (BU/BK), harness side and ground.
Yes
No
GO to L5.
------------------------------------------------- L5 CHECK FOR RESTORED NETWORK

COMMUNICATION WITH THE ACM AND SRM DISABLED
NOTE: When re-running the network test, the network test application must be closed first or the
screen display reverts back to the prior run network test results.
- Disconnect: Central Junction Box (CJB) Fuse 151 (15A).
- Repeat the network test.
- Do all other modules pass the network test?
Yes
INSTALL the removed fuse.
If the vehicle is equipped with a Speech Recognition Module (SRM), GO to L6.
If the vehicle is not equipped with a SRM, GO to Pinpoint Test E. See: Pinpoint Test E: The Audio
Control Module (ACM) Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to L7.

COMMUNICATION WITH THE ACM DISCONNECTED
Yes
CONNECT the ACM. GO to Pinpoint Test E. See: Pinpoint Test E: The Audio Control Module
(ACM) Does Not Respond To The Scan Tool
No
CONNECT the ACM. GO to Pinpoint Test F. See: Pinpoint Test F: The Speech Recognition
Module (SRM) Does Not Respond To The Scan Tool

COMMUNICATION WITH THE OCSM AND RCM DISABLED
- Disconnect: Central Junction Box (CJB) Fuse 162 (7.5A).
Yes
No

COMMUNICATION WITH THE OCSM DISCONNECTED
Do all other modules pass the network test?
Yes
CONNECT the OCSM. GO to Pinpoint Test G. See: Pinpoint Test G: The Occupant Classification
System Module (OCSM) Does Not Respond To The Scan Tool
No
CONNECT the OCSM. GO to Pinpoint Test H. See: Pinpoint Test H: The Restraints Control
Module (RCM) Does Not Respond To The Scan Tool
COMMUNICATION WITH THE IC, GEM AND TPMS MODULE DISABLED
- Disconnect: CJB Fuses 148 (7.5A) and 179 (7.5A).
Yes
INSTALL the removed fuses. GO to L10.
No
INSTALL the removed fuses. An intermittent fault is not present. GO to Pinpoint Test K. See:

COMMUNICATION WITH THE IC DISCONNECTED
Yes
CONNECT the IC. GO to Pinpoint Test C. See: Pinpoint Test C: The Instrument Cluster (IC) Does
Not Respond To The Scan Tool
No
CONNECT the IC. GO to L11.

COMMUNICATION WITH THE GEM DISCONNECTED

-
Do all other modules pass the network test?
Yes
CONNECT the GEM. GO to Pinpoint Test J. See: Pinpoint Test J: The Generic Electronic Module
(GEM) Does Not Respond To The Scan Tool
No
CONNECT the GEM. GO to Pinpoint Test I. See: Pinpoint Test I: The Tire Pressure Monitoring
System (TPMS) Module Does Not Respond To The Scan Tool
-------------------------------------------------
Pinpoint Test M: No High Speed Controller Area Network (HS-CAN) Communication, All Modules
Are Not Responding
Pinpoint Tests
Are Not Responding
Normal Operation
The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable
- Fuse
- ABS module
- Instrument Cluster (IC)
- Steering Angle Sensor Module (SASM) (if equipped)
- PCM
PINPOINT TEST M: NO HS-CAN COMMUNICATION, ALL MODULES ARE NOT RESPONDING
Refer to Battery.
------------------------------------------------- M1 CHECK THE DLC PINS FOR DAMAGE

- Ignition OFF.
Yes
GO to M2.
No
------------------------------------------------- M2 CHECK THE HS-CAN TERMINATION RESISTANCE
Yes
GO to M3.
No
GO to M5.
------------------------------------------------- M3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS

harness side and ground; and between the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH),
harness side and ground.
Yes
CONNECT the negative battery cable. GO to M4.
No
GO to M15.

- Ignition ON.
- Measure the voltage between the DLC C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness
side and ground; and between the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness
side and ground.

Yes
No
The HS-CAN has tested within specifications. GO to Pinpoint Test N to test for an intermittent
network fault condition. See: Pinpoint Test N: Intermittent No High Speed Controller Area Network
(HS-CAN) Communication, One Or More Modules Are Not Respond
------------------------------------------------- M5 CHECK THE HS-CAN TERMINATION RESISTOR

Yes
GO to M6.
No
GO to M9.
------------------------------------------------- M6 CHECK THE HS-CAN TERMINATION RESISTOR WITH

THE PCM DISCONNECTED
Yes
GO to M7.
No
GO to M8.
------------------------------------------------- M7 CHECK THE HS-CAN CIRCUITS BETWEEN THE PCM

- Measure the resistance between the PCM C175b-59, circuit 4-EC7 (GY/RD), harness side and
the DLC C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness side.
- Measure the resistance between the PCM C175b-43, circuit 5-EC7 (BU/RD), harness side and
the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness side.
Yes
No
------------------------------------------------- M8 CHECK THE HS-CAN CIRCUITS BETWEEN THE DLC

harness side and the IC C220b-23, circuit 4-EC8 (GY/VT), harness side.
- Measure the resistance between the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH),
harness side and the IC C220b-24, circuit 5-EC8 (BU/WH), harness side.

Yes
No

FOR A SHORT TOGETHER
Yes
GO to M11.
No
GO to M10.
------------------------------------------------- M10 CHECK THE HS-CAN CIRCUITS FOR AN OPEN AT

THE DLC
Yes
REPAIR the DLC or REPAIR the circuit in question. CONNECT the negative battery cable. CLEAR
the DTCs. REPEAT the network test with the scan tool.
No
A capacitor internal to a module may still be draining causing irregular resistance readings. WAIT 5
minutes. REPEAT the pinpoint test.
FOR A SHORT TOGETHER WITH THE PCM DISCONNECTED
Yes
GO to M12.
No
FOR A SHORT TOGETHER WITH THE ABS MODULE DISCONNECTED
- Disconnect: ABS Module C135 or C155.
Yes
If the vehicle is equipped with a Steering Angle Sensor Module (SASM), GO to M13.
If the vehicle is not equipped with an SASM, GO to M14.
No
FOR A SHORT TOGETHER WITH THE SASM DISCONNECTED
- Disconnect: SASM C226.
Yes
GO to M14.
No
FOR A SHORT TOGETHER WITH THE IC DISCONNECTED
Yes
No
FOR A SHORT TO GROUND WITH THE PCM DISCONNECTED
Yes
No
GO to M16.
FOR A SHORT TO GROUND WITH THE ABS MODULE DISCONNECTED
- Disconnect: ABS Module C135 or C155.
Yes
No
If the vehicle is equipped with a Steering Angle Sensor Module (SASM), GO to M17.
If the vehicle is not equipped with an SASM, GO to M18.
FOR A SHORT TO GROUND WITH THE SASM DISCONNECTED
- Disconnect: SASM C226.
Yes
No
GO to M20.
FOR A SHORT TO GROUND WITH THE IC DISCONNECTED
Yes
No
------------------------------------------------- M19 CHECK FOR CORRECT PCM OPERATION
- Check for: -
corrosion
- damaged pins
- pushed-out pins
Yes
INSTALL a new PCM. REFER to Computers and Control Systems. CLEAR the DTCs. REPEAT the
No
------------------------------------------------- M20 CHECK FOR CORRECT ABS MODULE OPERATION
- Disconnect the ABS module connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the ABS module connector and make sure it seats correctly.
Yes
INSTALL a new ABS module. REFER to Antilock Brakes / Traction Control Systems. CONNECT all
No
scan tool.
------------------------------------------------- M21 CHECK FOR CORRECT SASM OPERATION
- Disconnect the SASM connector.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect the SASM connector and make sure it seats correctly.
Yes
INSTALL a new SASM. REFER to Antilock Brakes / Traction Control Systems. CONNECT all
No
scan tool.
------------------------------------------------- M22 CHECK FOR CORRECT IC OPERATION
- Disconnect all the IC connectors.
- Check for: -
corrosion
- damaged pins
- pushed-out pins
- Connect all the IC connectors and make sure they seat correctly.
Yes
INSTALL a new IC. REFER to Instrument Panel, Gauges and Warning Indicators. CONNECT all
No
scan tool.
-------------------------------------------------
Pinpoint Test N: Intermittent No High Speed Controller Area Network (HS-CAN) Communication,
One Or More Modules Are Not Respond
Pinpoint Tests
Pinpoint Test N: Intermittent No High Speed Controller Area Network (HS-CAN) Communication,
One Or More Modules Are Not Responding During Network Test
Normal Operation
The High Speed Controller Area Network (HS-CAN) uses an unshielded twisted pair cable.
In the event that either the HS-CAN (+) or HS-CAN (-) circuit becomes open to a module on the
network, unreliable network communication to all modules on the network may result.
PINPOINT TEST N: INTERMITTENT NO HS-CAN COMMUNICATION, ONE OR MORE

MODULES ARE NOT RESPONDING DURING NETWORK TEST
NOTE: Various modules set network DTCs during this test procedure. Clear DTCs from all
modules after the diagnostic procedure is completed.
Refer to Battery.
------------------------------------------------- N1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.

Yes
GO to N2.
No
------------------------------------------------- N2 CHECK THE HS-CAN TERMINATION RESISTANCE
Yes
GO to N3.
No
GO to Pinpoint Test M. See: Pinpoint Test M: No High Speed Controller Area Network (HS-CAN)
Communication, All Modules Are Not Responding
------------------------------------------------- N3 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS

Yes
GO to N4.
No
GO to Pinpoint Test M. See: Pinpoint Test M: No High Speed Controller Area Network (HS-CAN)
Communication, All Modules Are Not Responding
------------------------------------------------- N4 CHECK THE HS-CAN (+) AND HS-CAN (-) CIRCUITS
- Connect: Negative Battery Cable.
- Ignition ON.
- Measure the voltage between the DLC C251-6, circuit 4-EC7 (GY/RD)/4-EC8 (GY/VT), harness
side and ground; and between the DLC C251-14, circuit 5-EC7 (BU/RD)/5-EC8 (BU/WH), harness
side and ground.
Yes
No
GO to N5.
------------------------------------------------- N5 CHECK FOR RESTORED COMMUNICATION WITH

THE PCM DISABLED
NOTE: An Integrated Diagnostic System (IDS) session must be established prior to disabling the
PCM in this test step. If the PCM has failed communication during multiple attempts to identify the
vehicle, first identify the vehicle manually by entering a PCM part number, calibration number or
tear tag when prompted by the IDS.
NOTE: When a vehicle is manually identified by a PCM part number, calibration number or tear
tag, the IDS does not automatically run a network test. The network test must be manually selected
and run.
- Disconnect: Battery Junction Box (BJB) Fuses 5 (10A), 28 (15A) and 35 (10A).
Yes
INSTALL the removed fuses. GO to Pinpoint Test A. See: Pinpoint Test A: The PCM Does Not
Respond To The Scan Tool
No
INSTALL the removed fuses. GO to N6.
------------------------------------------------- N6 CHECK FOR RESTORED NETWORK

COMMUNICATION WITH THE ABS MODULE AND SASM DISABLED
- Disconnect: BJB Fuse 15 (20A) and Central Junction Box (CJB) Fuse 161 (7.5A).
Yes
INSTALL the removed fuse.
If the vehicle is equipped with stability control, GO to N7.
If the vehicle is not equipped with stability control, GO to Pinpoint Test B. See: Pinpoint Test B: The
ABS Module Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. GO to N8.

COMMUNICATION WITH THE SASM DISCONNECTED
- Disconnect: Steering Angle Sensor Module (SASM) C226.
Yes
INSTALL a new SASM. REFER to Antilock Brakes / Traction Control Systems.
No
CONNECT the SASM. GO to Pinpoint Test B. See: Pinpoint Test B: The ABS Module Does Not
Respond To The Scan Tool

COMMUNICATION WITH THE IC DISABLED
- Disconnect: CJB Fuses 148 (7.5A) and 179 (7.5A).
Yes
INSTALL the removed fuses. GO to Pinpoint Test C. See: Pinpoint Test C: The Instrument Cluster
(IC) Does Not Respond To The Scan Tool
No
INSTALL the removed fuse. An intermittent fault is not present. GO to Pinpoint Test M. See:
Are Not Responding
-------------------------------------------------
Pinpoint Test O: No Power To The Scan Tool
Pinpoint Tests
Pinpoint Test O: No Power To The Scan Tool
Normal Operation
The scan tool is connected to the Data Link Connector (DLC) to communicate with the High Speed
Controller Area Network (HS-CAN) and Medium Speed Controller Area Network (MS-CAN).
A loss of ground or poor ground at the DLC may result in HS-CAN or MS-CAN faults while the scan
tool is connected.
- Fuse
- DLC
- Scan tool
PINPOINT TEST O: NO POWER TO THE SCAN TOOL
and verification before proceeding with the Pinpoint Test. See: Initial Inspection and Diagnostic
Refer to Battery.
------------------------------------------------- O1 CHECK THE DLC PINS FOR DAMAGE
- Ignition OFF.
- Inspect the DLC pins 4, 5 and 16 for damage.
- Are DLC pins 4, 5 and 16 OK?
Yes
GO to O2.
No
REPAIR the DLC as necessary. REPEAT the network test with the scan tool.
------------------------------------------------- O2 CHECK THE VOLTAGE TO THE SCAN TOOL

VOLTAGE SUPPLY CIRCUIT FOR AN OPEN
- Measure the voltage between the DLC C251-16, circuit 30-RA1 (RD), harness side and ground.
Yes
GO to O3.
No
VERIFY the Battery Junction Box (BJB) fuse 6 (15A) is OK. If OK, REPAIR the circuit. If not OK,
REFER to the Wiring Diagrams to identify the possible causes of the circuit short. REPEAT the
network test with the scan tool. See: Diagrams/Electrical Diagrams/Diagrams By Number
------------------------------------------------- O3 CHECK THE DLC GROUND CIRCUITS FOR AN OPEN
- Measure the resistance between the DLC C251-4, circuit 31-RA1 (BK), harness side and ground;
and between the DLC C251-5, circuit 91-RA1 (BK/OG), harness side and ground.
Yes
REPAIR the scan tool. CONNECT the negative battery cable. REPEAT the network test with the
scan tool.
No
REPAIR the circuit in question. CONNECT the negative battery cable. REPEAT the network test
with the scan tool.
-------------------------------------------------
Information Bus: Programming and Relearning
Programmable Module Installation (PMI) Using the Integrated Diagnostic System (IDS) When the
Original Module is Available
NOTE: Following module installation, some modules require a separate learning procedure be
carried out. For adaptive learning and calibration instructions, refer to the specific module removal
1. Connect the IDS and identify the vehicle as normal.
2. From the Toolbox icon, select Module Programming and press the check mark.
3. Select Programmable Module Installation.
4. Select the module that is being replaced.
5. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check
mark.
6. Install the new module and press the check mark.
7. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check
mark.
8. The IDS downloads the data into the new module and displays Module Configuration Complete.
9. Test module for correct operation.
Original Module is NOT Available
1. Install the new module.
5. Select the module that was replaced.

mark.
mark.
8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center.
Retrieve the data from the technician service
publication website at this time and press the check mark.
9. Enter the module data and press the check mark.
10. The IDS downloads the data into the new module and displays Module Configuration
Complete.

Information > Testing and Inspection > Page 2203
Information Bus: Service and Repair
Original Module is Available
4. Select the module that is being replaced.
mark.
6. Install the new module and press the check mark.
mark.
8. The IDS downloads the data into the new module and displays Module Configuration Complete.
Original Module is NOT Available
1. Install the new module.
5. Select the module that was replaced.

mark.
mark.
8. If the data is not available, the IDS displays a screen stating to contact the As-Built Data Center.
Retrieve the data from the technician service
publication website at this time and press the check mark.
9. Enter the module data and press the check mark.
10. The IDS downloads the data into the new module and displays Module Configuration
Complete.

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
System) > Component Information > Testing and Inspection > Relays - Micro
System) > Component Information > Testing and Inspection > Relays - Micro > Page 2216
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
concern is present.
- For all MIL concerns, go to Symptom Charts. See: Testing and Inspection/Symptom Related
Diagnostic Procedures
DTC P1000 is set.

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Locations
Sensor > Component Information > Locations > Page 2225

Typical MAP Sensor

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Temperature Sensor For ECM

Typical EOT Sensor

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Heated Oxygen Sensor(HO2S) #11
Information > Locations > Heated Oxygen Sensor(HO2S) #11 > Page 2235
Information > Diagrams > Heated Oxygen Sensor (HO2S) #12

Information > Diagrams > Heated Oxygen Sensor (HO2S) #12 > Page 2238

Information > Description and Operation > Heated Oxygen Sensor (HO2S)
Typical HO2S
Information > Description and Operation > Heated Oxygen Sensor (HO2S) > Page 2241
accuracy.
Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Exploded View
Information > Service and Repair > Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page
2244
removal.

2245
retainer.
removal.

2246

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >

Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page 2253
Sensor
parking maneuvers.
Typical PSP Sensor


Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Description and Operation > Page 2258

Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Body Control Module > Component Information > Locations
and Control Systems > Body Control Module > Component Information > Locations > Page 2263

Removal
mode DTC is:
mechanisms.
Installation

and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation
Overview
information on the APP sensor, refer to Engine Control Components. See: Description and
and Control Systems > Electronic Throttle Control Module > Component Information > Description and Operation > Page
2273
2274
2275


and Control Systems > Engine Control Module > Component Information > Locations
and Control Systems > Engine Control Module > Component Information > Locations > Page 2279
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures
Description
reset.
completed.
misfire DTCs.
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 2290
Removal
(PATS).
Bus.
Installation


and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Relays -
Micro
Micro > Page 2296
Micro > Page 2297
Micro > Page 2298
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches -
Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2303

Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2304
2-Track APP Sensor
Electronic Throttle Control (ETC). See: Electronic Throttle Control Module/Description and
Operation
3-Track APP Sensor

Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations
Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 2308


(TCC) scheduling.
Typical MAF Sensor



Computers and Control Systems > Barometric Pressure Sensor > Component Information > Description and Operation
Computers and Control Systems > Brake Pressure Switch > Component Information > Description and Operation > Brake
Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

Computers and Control Systems > Brake Pressure Switch > Component Information > Description and Operation > Brake
Pedal Position (BPP) Switch > Page 2319
strategy.
Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations
Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2323


Computers and Control Systems > Clutch Switch, ECM > Component Information > Description and Operation

Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Description and Operation > Cylinder Head Temperature (CHT) Sensor
Typical CHT Sensor

Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Description and Operation > Cylinder Head Temperature (CHT) Sensor > Page 2334


Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2338
Typical CKP Sensor

Removal
sensor.
Installation

Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations
Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2347
Computers and Control Systems > Engine Temperature Sensor > Component Information > Locations > Page 2348
Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
Typical CHT Sensor

Cylinder Head Temperature (CHT) Sensor > Page 2351
Sensor


Page 2352
connector.

Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Tank and Filler
Pipe - Exploded View

Pipe - Exploded View > Page 2357
Fuel Pump Module
personal injury.
ring.
arm.

Fuel Level Sender
personal injury.

Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2366

Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2372


sensor.
efficiency.


Computers and Control Systems > Knock Sensor > Component Information > Locations
Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2378
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2385

Typical MAP Sensor

Computers and Control Systems > Oil Temperature Sensor For ECM > Component Information > Description and Operation

Typical EOT Sensor

Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor(HO2S)
#11
Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Heated Oxygen Sensor(HO2S)
#11 > Page 2395
Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#12

Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Heated Oxygen Sensor (HO2S)
#12 > Page 2398

Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated
Oxygen Sensor (HO2S)
Typical HO2S
Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Heated
Oxygen Sensor (HO2S) > Page 2401
accuracy.
Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen
Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Exploded View
Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View > Page 2404
removal.

retainer.
removal.


Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2410

Computers and Control Systems > Power Steering Pressure Switch > Component Information > Description and Operation
> Power Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

> Power Steering Pressure (PSP) Switch > Page 2413
Sensor
parking maneuvers.
Typical PSP Sensor

> Page 2414

Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and
Operation

Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and

Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Sensor (ETBTPS)
Throttle Control (ETC). See: Electronic Throttle Control Module/Description and Operation
Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation >
Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page 2423
Typical TP Sensor
Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations
Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
2427
2428
2429
Removal
cable.

2430
Installation
bolts.
1. "1" M1
2431
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor
generated.
Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Output
Shaft Speed (OSS) Sensor > Page 2436
Typical VSS
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
Throttle Control (ETC). See: Electronic Throttle Control Module/Description and Operation
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page
2441
Typical TP Sensor
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Switch/Sensor, A/T > Component Information > Locations > Page 2445
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Overview
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
VCT System
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor
generated.
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Output Shaft Speed (OSS) Sensor > Page 2458
Typical VSS
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Catalytic Converter: Description and Operation

CATALYST AND EXHAUST SYSTEMS
Overview
The catalytic converter and exhaust systems work together to control the release of harmful engine
exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen (N),
carbon dioxide (CO2) and water (H2O). However, it also contains carbon monoxide (CO), oxides of
nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). The major air pollutants
of CO, NOx, and HCs, and their emission into the atmosphere must be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, front heated
oxygen sensor (HO2S), rear exhaust pipe, catalyst HO2S, a muffler, and an exhaust tailpipe. The
catalytic converter is typically installed between the front and rear exhaust pipes. On some vehicle
applications, more than one catalyst is used between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the on board diagnostic (OBD) system strategy in the
powertrain control module (PCM). For information on the OBD catalyst monitor, refer to the
description for the Catalyst Efficiency Monitor. See: Computers and Control Systems/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Catalyst Efficiency Monitor
Only two HO2Ss are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the
catalyst are used for primary fuel control while the sensors after the catalyst (HO2S12/HO2S22)
are used to monitor catalyst efficiency.
Typical V-Engine
Information > Description and Operation > Page 2463
Typical In-Line Engine
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst also enables a chemical reaction to occur at a lower temperature. The
concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
ceramic honeycomb structure saturated with catalytically active precious metals. As the exhaust
gases come in contact with the catalyst, they are changed into mostly harmless products. The
catalyst initiates and speeds up heat producing chemical reactions of the exhaust gas components
so they are used up as much as possible.
Light Off Catalyst
As the catalyst heats up, converter efficiency rises rapidly. The point at which conversion efficiency
exceeds 50% is called catalyst light off. For most catalysts this point occurs at 246°C to 302°C
(475°F to 575°F). A fast light catalyst is a three way catalytic converter (TWC) that is located as
close to the exhaust manifold as possible. Because the light off catalyst is located close to the
exhaust manifold it lights off faster and reduces emissions more quickly than the catalyst located
under the body. Once the catalyst lights off, the catalyst quickly reaches the maximum conversion
efficiency for that catalyst.
Three Way Catalytic Converter (TWC) Conversion Efficiency

A TWC requires a stoichiometric air/fuel ratio, 14.7 pounds of air to 1 pound of gasoline (14.7:1),
for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be
tightly controlled with a narrow window of stoichiometry. Deviations outside of this window greatly
decrease the conversion efficiency. For example a rich mixture decreases the HC and CO
conversion efficiency while a lean mixture decreases the NOx conversion efficiency.
For vehicles using E85 the required air/fuel ratio is 9.8:1. Other gasoline/ethanol mixtures require a
variable air/fuel ratio between 14.7:1 to 9.8:1 dependent on the percentage of ethanol content.
TWC Conversion Efficiency Chart
Exhaust System
The exhaust system conveys engine emissions from the exhaust manifold to the atmosphere.
Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter
through the front exhaust pipe. A HO2S is mounted on the front exhaust pipe before the catalyst.
The catalytic converter reduces the concentration of CO, unburned HCs, and NOx in the exhaust
emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic
converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler.
Finally, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
Information > Description and Operation > Page 2464
Typical Bank 1 Catalyst 2 HO2S Configuration
Underbody Catalyst
The underbody catalyst is located after the light off catalyst. The underbody catalyst may be in line
with the light off catalyst, or the underbody catalyst may be common to 2 light off catalysts, forming
a Y pipe configuration. For an exact configuration of the catalyst and exhaust system for a specific
vehicle, refer to the Exhaust System for the exhaust system exploded view.
Three Way Catalytic (TWC) Converter
The TWC contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The
TWC catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of
NOx. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio
at or close to stoichiometry.
Exhaust Manifold Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
The HO2Ss provide the powertrain control module (PCM) with information related to the oxygen
content of the exhaust gas. For additional information on the HO2S, refer to Engine Control
Components. See: Computers and Control Systems/Description and Operation/Engine Control
Components
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Information > Service and Repair > Catalytic Converter
Catalytic Converter: Service and Repair Catalytic Converter
Catalytic Converter
of the rubber.
To service the underbody catalytic converter, refer to the Muffler and Tailpipe See: Engine, Cooling
and Exhaust/Exhaust System/Muffler/Service and Repair/Muffler and Tailpipe procedure.
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
3. Remove the 2 upper catalytic converter heat shield bolts.
4. Remove the muffler and tailpipe. For additional information, refer to Muffler and Tailpipe See:
Engine, Cooling and Exhaust/Exhaust
System/Muffler/Service and Repair/Muffler and Tailpipe.
6. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these
instructions may cause damage to the exhaust
flexible pipe.
Support the exhaust flexible pipe with a support wrap or suitable splint.
Information > Service and Repair > Catalytic Converter > Page 2467
7. Remove the 2 lower bolts and position aside the catalytic converter heat shield.
9. Remove the engine support bracket-to-catalytic converter bolt.
10. Remove the 2 engine support bracket-to-engine block bolts.
- Remove the engine support bracket.
11. Detach the 2 catalytic converter exhaust hanger isolators.
12. Remove and discard the 2 exhaust manifold-to-catalytic converter nuts.
- Remove the catalytic converter.
- Install new gaskets and nuts.

Catalytic Converter: Service and Repair Exhaust System - Exploded View

Catalytic Converter: Service and Repair Catalytic Converter - Underbody
Catalytic Converter - Underbody
1. To service the underbody catalytic converter, refer to the Muffler and Tailpipe See: Engine,
Cooling and Exhaust/Exhaust System/Muffler/Service
and Repair/Muffler and Tailpipe procedure.

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Diagrams
Canister Purge Control Valve: Diagrams
Canister Purge Control Valve > Component Information > Diagrams > Page 2475
Canister Purge Control Valve > Component Information > Description and Operation > Evaporative Emission (EVAP)
Canister Purge Valve
Canister Purge Control Valve: Description and Operation Evaporative Emission (EVAP) Canister
Purge Valve
Evaporative Emission (EVAP) Canister Purge Valve
The EVAP canister purge valve is part of the enhanced EVAP system controlled by the PCM. This
valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during
various engine operating modes. The EVAP canister purge valve is a normally closed valve. The
EVAP canister purge valve controls the flow of vapors by way of a solenoid, eliminating the need
for an electronic vacuum regulator and vacuum diaphragm. For E-Series, Escape/Mariner,
Expedition, F-Series, Fusion 2.5L, Fusion 3.0L, Milan and Navigator, the PCM outputs a duty cycle
between 0% and 100% to control the EVAP canister purge valve. For all others, the PCM outputs a
variable current between 0 and 1,000 mA to control the EVAP canister purge valve.
Typical EVAP Canister Purge Valve

Canister Purge Control Valve > Component Information > Description and Operation > Evaporative Emission (EVAP)
Canister Purge Valve > Page 2478
Canister Purge Control Valve: Description and Operation Evaporative Emission (EVAP) Canister
Purge Check Valve
Evaporative Emission (EVAP) Canister Purge Check Valve
The EVAP canister purge check valve is used on turbocharged engines to prevent boost pressure
from forcing open the EVAP canister purge valve and entering the EVAP system. The valve is open
under normal engine vacuum. The valve closes during boost conditions to prevent the fuel tank
from being pressurized and hydrocarbons forced out of the EVAP system into the atmosphere
through the EVAP canister vent valve. When the engine is off, or at atmospheric pressure, the
EVAP canister purge check valve is in an indeterminate state. The EVAP canister purge check
valve is an integral part of the purge valve assembly.
Typical EVAP Canister Purge Check Valve

Canister Purge Control Valve > Component Information > Description and Operation > Page 2479
Canister Purge Control Valve: Service and Repair
Evaporative Emission Canister Purge Valve
personal injury.
2. Remove the 2 retainers, release the clip and remove the heat shield.
3. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
4. Disconnect the 2 fuel vapor jumper tube-to- EVAP canister purge valve quick connect couplings.
For additional information, refer to Fuel
5. Press the locking tab and remove the EVAP canister purge valve from the bracket.
Canister Purge Control Valve > Component Information > Description and Operation > Page 2480
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test See: Testing and Inspection.
Evaporative Emission Control Canister > Component Information > Service and Repair
Evaporative Emission Control Canister: Service and Repair
Evaporative Emission Canister
personal injury.
1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
2. Disconnect the fuel vapor tube assembly-to-Evaporative Emission (EVAP) canister quick
connect coupling. For additional information, refer to
Fuel Delivery and Air Induction.
3. Disconnect the fuel vapor jumper tube-to-EVAP canister quick connect coupling. For additional
information, refer to Fuel Delivery and Air
Induction.
4. Remove the 3 nuts and the EVAP canister.
- Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Solenoid, Evaporative System > Component Information > Description and Operation
Leak Detection Solenoid: Description and Operation
Canister Vent (CV) Solenoid
During the evaporative emissions (EVAP) leak check monitor, the CV solenoid seals the EVAP
canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the
target vacuum in the fuel tank during the EVAP leak check monitor.
Typical Canister Vent (CV) Solenoid

Detection Valve, Evaporative System > Component Information > Locations
Leak Detection Valve: Locations
Detection Valve, Evaporative System > Component Information > Locations > Page 2490
Leak Detection Valve: Diagrams
Leak Detection Valve: Service and Repair

Evaporative Emission Canister Vent Solenoid
personal injury.
3. Position the Powertrain Lift under the fuel tank.

4. Remove the bolt and position the fuel tank straps aside.
5. NOTE: Clean the Evaporative Emission (EVAP) canister electrical connector and the immediate
Disconnect the EVAP canister vent solenoid electrical connector.
6. Depress the locking tab outward, rotate the EVAP canister vent solenoid clockwise and remove
it from the EVAP canister.
7. NOTE: Do not apply engine oil to the EVAP canister vent solenoid O-ring seal. Clean water may
be used to aid reassembly.
To install, reverse the removal procedure. -
Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Description and Operation
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid
The EGR vacuum regulator solenoid is an electromagnetic device used to regulate the vacuum
supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a
disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed
through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is
vented through the solenoid vent to the atmosphere. At 0% duty cycle (no electrical signal applied),
the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR
valve.
EGR Vacuum Regulator Solenoid

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

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
EGR Valve: Locations
EGR Valve: Diagrams

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

> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 2507
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) System Module (ESM)
Exhaust Gas Recirculation (EGR) System Module (ESM)
The ESM is an integrated differential pressure feedback EGR system that functions in the same
manner as a conventional differential pressure feedback EGR system. The various system
components have been integrated into a single component called the ESM. The flange of the valve
portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the metering
orifice. This arrangement increases system reliability, response time, and system precision. By
relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream
pressure signal measures manifold absolute pressure (MAP). This MAP signal is used for EGR
correction and inferred barometric pressure (BARO) at ignition on. The system provides the PCM
with a differential pressure feedback EGR signal that is identical to a traditional differential pressure
feedback EGR system.
ESM
> Component Information > Description and Operation > Electric Exhaust Gas Recirculation (EEGR) Valve > Page 2508
EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve
Exhaust Gas Recirculation (EGR) Valve
The EGR valve in the differential pressure feedback EGR system is a conventional,
vacuum-actuated valve. The valve increases or decreases the flow of EGR. As vacuum applied to
the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum
signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is
fully open at about 15 kPa (4.4 in-Hg).
Since EGR flow requirement varies greatly, providing repair specifications on flow rate is
impractical. The on board diagnostic (OBD) system monitors the EGR valve function and triggers a
diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not
measured directly as part of the diagnostic procedures.
Typical EGR Valve

EGR Valve: Service and Repair
Exhaust Gas Recirculation (EGR) Valve
1. Drain the cooling system. For additional information, refer to Cooling System &/or Engine Block
Heater.
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and
Air Induction.
3. Disconnect the 2 engine wiring harness electrical connectors and release them from the bracket.
4. Disconnect the center PCM electrical connector.
5. Disconnect the EGR valve electrical connector.
6. Release the clamp and remove the upper radiator hose from the coolant outlet adapter.
7. Release the clamp and remove the heater hose from the EGR valve.
8. Remove the 2 bolts and the EGR valve.
cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces
of the Exhaust Gas Recirculation (EGR) valve gasket.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and
prepare the mating surfaces.
Clean the mating surfaces of any residual gasket material.
- Install a new EGR valve gasket.
11. Fill and bleed the cooling system. For additional information, refer to Cooling System &/or
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Description and Operation

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Description and Operation > Page 2514

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Oil
Separator > Component Information > Service and Repair
Oil Separator: Service and Repair
Crankcase Vent Oil Separator
2. Remove the bypass hose from the retainer clip and position aside.
3. NOTE: Inspect the crankcase vent oil separator gasket for damage and replace if necessary.
Remove the 8 bolts, crankcase vent oil separator and the gasket.
4. NOTE: Clean and inspect the gasket mating surfaces.
NOTE: Inspect the crankcase vent oil separator gasket for damage. Replace as necessary.

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation

Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Description and Operation >
Page 2523

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Specifications
Fuel Pressure
pressure........................................................................393-413 kPa (57-60 psi)
personal injury.
and Repair.
pressure release.
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Accelerator Pedal: Service and Repair
Accelerator Pedal

1. Disconnect the accelerator pedal sensor electrical connector.
2. Remove the 2 nuts and the accelerator pedal and sensor assembly.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor >

2-Track APP Sensor
3-Track APP Sensor

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Diagrams

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >


(TCC) scheduling.
Typical MAF Sensor



Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator >
Fuel Filler Cap Warning Indicator: Description and Operation
Check Fuel Cap Indicator
The check fuel cap indicator is a communications network message sent by the PCM. The PCM
sends the message to illuminate the lamp when the strategy determines there is a concern in the
EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly.
This is detected by the inability to pull vacuum in the fuel tank after a fueling event.
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Fuel Injector 1
Fuel Injector: Diagrams Fuel Injector 1
Information > Diagrams > Fuel Injector 1 > Page 2563
Fuel Injector: Description and Operation
Fuel Injectors
NOTICE: Do not apply battery positive (B+) voltage directly to the fuel injector electrical connector
terminals. The solenoids may be damaged internally in a matter of seconds.
The fuel injector is a solenoid-operated valve that meters fuel flow to the engine. The fuel injector is
opened and closed a constant number of times per crankshaft revolution. The amount of fuel is
controlled by the length of time the fuel injector is held open.
The fuel injector is normally closed, and is operated by a 12-volt source from either the powertrain
control module (PCM) power relay or fuel pump relay. The ground signal is controlled by the PCM.
The injector is the deposit resistant injector (DRI) type and does not have to be cleaned. Install a
new fuel injector if the flow is checked and found to be out of specification.
Typical Fuel Injector

Fuel Injectors - Direct Injection
The gasoline direct fuel injection fuel injector delivers fuel directly into the cylinder under high
pressure. Each injector is controlled by 2 circuits from the PCM.
A boosted voltage supply, up to 65 volts, is generated in the PCM and used to initially open the
injector. The injector driver controls three transistor switches that apply the boost voltage to open
the injector and then modulates the current to hold the injector open. If boost voltage is unavailable,
the proper injector opening current may not be generated in the time required.
The PCM contains a smart driver that monitors and compares high side and low side injector
currents to diagnose numerous concerns. Each fuel injector high side circuit is paired inside the
PCM with another fuel injector high side circuit. All injector concerns are reported with a single DTC
per injector.
Typical Direct Fuel Injection Fuel Injector

Information > Service and Repair > Fuel Rail and Fuel Injector - Exploded View
Fuel Injector: Service and Repair Fuel Rail and Fuel Injector - Exploded View
Fuel Rail and Fuel Injector - Exploded View

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Fuel Line Coupler: Service and Repair
Quick Connect Coupling
Disconnect - Type I
personal injury.
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to
remove any foreign material from the connector retaining clip area before separating from the tube
or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the
tube before inserting the tube into the connector.
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances.
It is essential that absolute cleanliness is observed when working with these components or
component damage can occur. Always install plugs to any open orifices or tubes.
NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For
additional information, refer to Fuel System Pressure
Release See: Fuel Filter/Fuel Pressure Release/Service and Repair.
2. If servicing an Evaporative Emission (EVAP) or fuel-related component, disconnect the battery

ground cable. For additional information, refer to
Battery.
3. Depress the locking tab and release the quick connect coupling from the tube.
Connect - Type I
1. NOTE: Apply clean engine oil to the quick connect coupling O-ring seals.
Install the quick connect coupling onto the tube until it is fully seated.
2. Pull on the quick connect coupling and tube to make sure it is securely fastened.
3. If servicing an EVAP or fuel-related component, connect the battery ground cable. For additional
information, refer to Battery.
Disconnect - Type II
personal injury.
2. If servicing an EVAP or fuel-related component, disconnect the battery ground cable. For
additional information, refer to Battery.
3. Spread the legs of the retainer clip and pull it to the outward position.
4. Depress the retainer clip and disconnect the quick connect coupling from the tube.
Connect - Type II
2. Press the retainer clip into the quick connect coupling body until flush and the legs are locked in
place.
Disconnect - Type III
personal injury.
3. Position the secondary latch outward.

4. Squeeze both of the release tabs.
5. Remove the quick connect coupling from the tube.
Connect - Type III
2. Apply the secondary latch into the locked position.
Disconnect - Type IV
personal injury.
2. Release the lock tab on the quick connect coupling.
3. Separate the quick connect coupling from the fitting.
Connect - Type IV
Release the lock tab and install the quick connect coupling onto the fitting until fully seated.
2. Apply the lock tab into the latched position.

3. Pull on the quick connect coupling and fitting to make sure it is securely fastened.
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation > Fuel Rail Pressure (FRP) Sensor > Page 2586
Sensor
Typical FRPT Sensor

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications
Fuel Pressure
pressure........................................................................393-413 kPa (57-60 psi)
System Information > Specifications > Page 2591
personal injury.
and Repair.
System Information > Specifications > Page 2592
pressure release.
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service and Repair > Fuel Rail
Fuel Rail: Service and Repair Fuel Rail

Fuel Rail
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
personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air
Induction.
3. Disconnect the 4 fuel injector electrical connectors.
fuel jumper tube from the fuel rail
5. Remove the 2 bolts and the fuel rail and injectors.
6. 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.

> Service and Repair > Fuel Rail > Page 2605
Remove the fuel injector retaining clips and the fuel injectors.
- Remove and discard the O-ring seals.
7. NOTE: Install new O-ring seals and lubricate them with clean engine oil.

> Service and Repair > Fuel Rail > Page 2606
Fuel Rail: Service and Repair Fuel Rail and Fuel Injector - Exploded View
Fuel Rail and Fuel Injector - Exploded View

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Fuel Supply Line: Service and Repair Fuel Tank and Filler Pipe - Exploded View

Fuel Supply Line: Service and Repair Fuel Lines
Fuel Lines
personal injury.
1. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air
Induction.
3. WARNING: When handling fuel, always observe fuel handling precautions and be prepared in
the event of fuel spillage. Spilled fuel may
be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions
NOTE: Place absorbent toweling in the immediate surrounding area in case of any fuel spillage.
NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure.
Upon disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable
container.
Disconnect the fuel jumper tube-to-fuel supply tube quick connect coupling. For additional
information, refer to Fuel Delivery and Air Induction.
4. Disconnect the fuel vapor jumper tube-to-fuel vapor tube quick connect coupling. For additional
Induction.
5. Remove the front subframe. For additional information, refer to Frame.
6. Disconnect the fuel jumper tube-to-fuel supply tube quick connect coupling. For additional
information, refer to Fuel Delivery and Air Induction.
7. Disconnect the fuel vapor jumper tube-to-fuel vapor tube quick connect coupling. For additional
Induction.
8. Release the 5 fuel tube bundle retainer clips and remove the fuel supply and vapor tubes.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Fuel Filler Hose: Service and Repair Fuel Tank and Filler Pipe - Exploded View

Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe
Fuel Tank Filler Pipe
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.
personal injury.
3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the
thread disengages and position aside.
4. Insert a length of semi-rigid fuel drain tube into the fuel tank filler pipe as far as possible.
5. Attach the Fuel Storage Tanker to the fuel drain tube and remove any residual fuel in the fuel
tank filler pipe.
6. Remove the RR wheel and tire. For additional information, refer to Wheels and Tires.
7. Remove the retainers and the RR splash shield.
8. NOTE: Some residual fuel may remain in the fuel tank filler pipe. Carefully drain into a suitable
container.
Loosen the clamp and remove the fuel tank filler pipe hose from the fuel tank.

9. Disconnect the fuel tank filler pipe fresh air hose from the Evaporative Emission (EVAP) canister.
10. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect
coupling. For additional information, refer to Fuel
11. Remove the 2 bottom fuel tank filler pipe bracket bolts.
12. Remove the center fuel tank filler pipe bracket bolt.
13. Remove the top fuel tank filler pipe bracket bolt.
14. Remove the fuel tank filler pipe.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Description and Operation > Fuel Pump (FP) Module

Component Information > Description and Operation > Fuel Pump (FP) Module > Page 2631
tank fill levels.

Fuel Pump Module
personal injury.
1. Remove the fuel tank. For additional information, refer to Fuel Tank See: Service and
Repair/Removal and Replacement/Fuel Tank.
ring.
arm.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Fuel Tank Unit: Locations
Fuel Tank Unit: Diagrams
Information > Description and Operation > Fuel Pump (FP) Module
Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module

Information > Description and Operation > Fuel Pump (FP) Module > Page 2645
Fuel Tank Unit: Description and Operation Fuel Pump (FP) Module and Reservoir
tank fill levels.
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Typical FRPT Sensor

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator -
Electronic > Component Information > Description and Operation
Idle Speed/Throttle Actuator - Electronic: Description and Operation
Idle Air Control (IAC) Valve
NOTE: The IAC valve assembly is not adjustable and cannot be cleaned.
The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC
valve assembly meters intake air around the throttle plate through a bypass within the IAC valve
assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals
the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the
IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or
decreases the IAC duty cycle in order to achieve the desired RPM.
The PCM uses the IAC valve assembly to control: -
no touch start
- cold engine fast idle for rapid warm-up
- idle (corrects for engine load)
- stumble or stalling on deceleration (provides a dashpot function)
- over-temperature idle boost

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Typical IFS Switch


Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Intake Air System Components - Exploded View
Intake Air Duct: Service and Repair Intake Air System Components - Exploded View

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair > Intake Air System Components - Exploded View > Page 2663
Intake Air Duct: Service and Repair Air Cleaner Outlet Pipe
Air Cleaner Outlet Pipe
1. Disconnect the crankcase ventilation tube-to-Air Cleaner (ACL) outlet pipe quick connect
coupling. For additional information, refer to Fuel
2. Loosen the clamp and disconnect the power brake booster aspirator tube-to-ACL outlet tube.
3. Loosen the clamp and disconnect the ACL outlet pipe from the ACL cover.
4. Loosen the clamp and disconnect the ACL outlet pipe from the Throttle Body (TB).
5. NOTE: The ACL outlet pipe should be securely sealed to prevent unmetered air from entering
the engine.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
System) > Component Information > Testing and Inspection > Relays - Micro
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Relays - Micro
and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Relays - Micro > Page 2678
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > Relays -
Micro
Micro > Page 2686
Micro > Page 2687
Micro > Page 2688
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2693

Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2694
2-Track APP Sensor
3-Track APP Sensor

Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 2698


(TCC) scheduling.
Typical MAF Sensor



Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail
Pressure (FRP) Sensor

Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation > Fuel Rail
Pressure (FRP) Sensor > Page 2706
Sensor
Typical FRPT Sensor

Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Description and Operation
Typical FRPT Sensor

Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2713
Typical IFS Switch


Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Electronic
Throttle Body Throttle Position Sensor (ETBTPS) > Page 2721
Typical TP Sensor
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Throttle Body: Service and Repair
Throttle Body
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Fuel Delivery and
Air Induction.
2. Disconnect the electronic throttle control electrical connector.
3. Remove the 4 bolts and the Throttle Body (TB).
- Inspect the TB gasket and install new as necessary.
- To install, tighten to 10 Nm (89 lb-in) in the sequence shown.

Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS)
Sensor (ETBTPS)
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Electronic Throttle Body Throttle Position Sensor (ETBTPS) > Page
2729
Typical TP Sensor
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Actuator > Component Information > Description and Operation
Variable Induction Control Actuator: Description and Operation
Intake Manifold Tuning Valve (IMTV)
WARNING: Substantial opening and closing torque is applied by this system. To prevent injury, be
careful to keep fingers away from lever mechanisms when actuated. Failure to follow these
instructions may result in personal injury.
The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator
controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with
this system to indicate shutter position.
The motorized IMTV unit is not energized below a calibrated RPM. The shutter is in the closed
position to prevent airflow blend from occurring in the intake manifold. The motorized unit is
energized above a calibrated RPM. The motorized unit is commanded on by the PCM initially at a
100 percent duty cycle to move the shutter to the open position, and then falling to approximately
50 percent to continue to hold the shutter open.
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order..........................................................................................................................................
.........................................................................1-3-4-2
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component


Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Typical CKP Sensor

Removal
sensor.
Installation

Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Coil On Plug (COP) 1
Ignition Coil: Diagrams Coil On Plug (COP) 1
> Coil On Plug (COP) 1 > Page 2758
Ignition Coil: Diagrams Ignition Transformer Capacitor
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil On Plug (COP)
Ignition Coil: Description and Operation Coil On Plug (COP)
Coil On Plug (COP)
The COP ignition operates similar to a standard coil pack ignition except each plug has 1 coil per
plug. The COP has 3 different modes of operation: engine crank, engine running, and CMP failure
mode effects management (FMEM). For additional information, refer to Ignition Systems. See:
Description and Operation/Ignition Systems
Typical Coil On Plug (COP)

Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Description and Operation > Coil On Plug (COP) > Page 2769
Ignition Coil: Description and Operation Coil Pack
Coil Pack
The PCM provides a grounding switch for the coil primary circuit. When the switch is closed,
voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil.
The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the
secondary coil windings and firing the spark plug. The spark plugs are paired so that as 1 spark
plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next
time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine
firing order.
Coil packs come in 4-tower, 6-tower horizontal and 6-tower series 5 models. Two adjacent coil
towers share a common coil and are called a matched pair. For 6-tower coil pack (6 cylinder)
applications, the matched pairs are 1 and 5, 2 and 6, and 3 and 4. For 4-tower coil pack (4 cylinder)
applications, the matched pairs are 1 and 4 and 2 and 3.
When the coil is fired by the PCM, spark is delivered through the matched pair towers to their
respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires
on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil
is fired, the situation is reversed. The next pair of spark plugs fire according to the engine firing
order.
Typical 4-Tower Coil Pack
Typical 6-Tower Coil Pack

Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service
and Repair > Engine Ignition Components - Exploded View
Ignition Coil: Service and Repair Engine Ignition Components - Exploded View

Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service
and Repair > Engine Ignition Components - Exploded View > Page 2772
Ignition Coil: Service and Repair Ignition Coil-On-Plug
Ignition Coil-On-Plug
1. Disconnect the 4 ignition coil-on-plug electrical connectors.
2. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and
ease removal.
Remove the 4 bolts and the ignition coils.

3. Inspect the coil boots for rips, nicks or tears. Remove and discard any damaged coil boots.
- To install, slide the new coil boot onto the coil until it is fully seated at the top of the coil.
- Apply a small amount of dielectric compound to the inside of the ignition coil boots prior to
attaching to the spark plugs.
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information >
Locations
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing
and Inspection > Relays - Micro
and Inspection > Relays - Micro > Page 2778
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations
Camshaft Position Sensor > Component Information > Locations > Page 2801


Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor > Component Information > Locations > Page 2808
Typical CKP Sensor

Removal
sensor.
Installation

Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal and Replacement

Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal and Replacement > Page
2819
Assembly
2820

2821
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Knock Sensor (KS)
timing.

Knock Sensor (KS)

Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Gap
Spark Plug Gap....................................................................................................................................

....................................1.25-1.35 mm (0.049-0.053 in)
Specifications > Gap > Page 2833
Spark Plugs..........................................................................................................................................
........................................................12 Nm 106 (lb-in)
Spark Plug............................................................................................................................................
...............................................................AGSF32YPC
carbon fouling.
-



Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Engine Ignition Components - Exploded View

Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
and Repair > Engine Ignition Components - Exploded View > Page 2839
Spark Plugs
Ignition Coil/Service and Repair/Ignition
Coil-On-Plug.
the spark plugs.

Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams
Shift Solenoid: Diagrams

Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators -
Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Transmission Mode Indicator - A/T: Description and Operation
Transmission Control Indicator lamp (TCIL)
The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the
engagement or disengagement of overdrive.
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Description
and Operation > Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

and Operation > Brake Pedal Position (BPP) Switch > Page 2857
strategy.
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >

Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Locations > Output Shaft Speed (OSS) Sensor
Locations > Output Shaft Speed (OSS) Sensor > Page 2873
Diagrams > Output Shaft Speed (OSS) Sensor

Diagrams > Output Shaft Speed (OSS) Sensor > Page 2876

Service and Repair > Turbine Shaft Speed (TSS) Sensor
Removal
Air Induction.

Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 2879
Installation

Removal
- Remove the bolt.
Installation
2. Lower vehicle.
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids -
A/T > Shift Solenoid, A/T > Component Information > Diagrams

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
follows: -
Typical BPP Switch

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC >
strategy.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission
Dipstick - Dipstick Tube > Component Information > Service and Repair
Automatic Transmission Dipstick - Dipstick Tube: Service and Repair
Transaxle Filler Tube
Transaxle Filler Tube
Removal
1. Remove the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to Fuel
2. Remove the transmission fluid level indicator.
3. Remove the transaxle filler tube bolt.

Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 2901
4. Disconnect the throttle control electrical connector.
5. Disconnect the bottom PCM electrical connector.
6. Remove the power steering hose retainers and the wiring harness retainer from the transaxle
filler tube.
7. Remove the transaxle filler tube bolt, rotate the transaxle filler tube from under the throttle body
and remove the transaxle filler tube.
Installation
1. Inspect the transaxle filler tube O-ring for damage before installing the transaxle filler tube. If the
transaxle filler tube O-ring is damaged, install a
new transaxle filler tube O-ring. Lubricate the transaxle filler tube O-ring with clean transmission
fluid.
2. Install the transaxle filler tube and transaxle filler tube bolt.

Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 2902
3. Install the power steering hose retainers and the wiring harness retainer on the transaxle filler
tube.
4. Connect the bottom PCM electrical connector.
5. Connect the throttle control electrical connector.
6. Install the transaxle filler tube bolt.
7. Install the transmission fluid level indicator.
8. Install the ACL and outlet pipe assembly. For additional information, refer to Fuel Delivery and
Air Induction.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Fluid - A/T: Capacity Specifications
Capacity ...............................................................................................................................................
................................................. 7.1 quarts (6.7 liters) NOTE: Approximate dry-fill capacity including
transmission fluid cooling system, actual refill capacities will vary based on vehicle and
transmission fluid cooling system (i.e. coolers size, cooling lines, auxiliary cooler capacity). The
amount of transmission fluid and fluid level should be set by the indication on the dipstick's normal
range.
Fluid - A/T: Fluid Type Specifications
Ford Part Name - Motorcraft MERCON LV ATF
Ford Part Number - XT-10-QLV
Ford Specification - MERCON LV
NOTE: Automatic transmissions that require MERCON LV should only use MERCON LV fluid. Use
of any fluid other then the recommended fluid may cause transmission damage.
Information > Service and Repair > Transmission Fluid Exchange
Fluid - A/T: Service and Repair Transmission Fluid Exchange
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
2. Use the Heavy-Duty Transmission and Power Steering Fluid X-Changer to change the fluid.
3. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission
fluid cooler tube after the transmission fluid
cooler on the return tube. This will help remove any foreign material trapped in the transmission
fluid coolers.
4. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power
Steering Fluid X-Changer. Follow the manufacturer's
instructions included with the machine.
5. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission
and Power Steering Fluid X-Changer. Reconnect any
disconnected transmission fluid cooler tubes.
6. Using the scan tool with the engine running, check and make sure that the transmission is at
normal operating temperature 49°C-60°C (120°F-140°
F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is
needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.
Information > Service and Repair > Transmission Fluid Exchange > Page 2910
Fluid - A/T: Service and Repair 4F27E
Cooler, A/T.
reservoir.

2. Disconnect the transmission fluid cooler outlet tube from the transmission fluid cooler and
position it aside. For additional information, refer to
3. Attach a length of suitable drain hose to the transmission fluid cooler.
4. Insert the drain hose into a calibrated 10L (10.5 qt) container.
cooler tubes.
7. Remove the transmission fluid level indicator from the transaxle filler tube.

cooler tubes.
14. Remove the length of drain hose from the transmission fluid cooler.
15. Connect the transmission fluid cooler outlet tube to the transmission fluid cooler. For additional
information, refer to Transmission Cooler, A/T.
18. Install the transmission fluid level indicator into the transaxle filler tube.
Run the engine.
20. Check the transmission fluid level and fill if necessary.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Fluid Pan: Specifications
Install the transmission fluid pan. Tighten to........................................................................................

..............................................................................................................10 Nm (89 lb-in).
Fluid Pan: Service and Repair
Transmission Fluid Pan
Transmission Fluid Pan
Removal
2. NOTE: The transmission fluid pan is filled with transmission fluid and cannot be drained before
removing.
Remove the transmission fluid pan.
- Remove the bolts.
- Using a suitable tool, separate the bead of sealer.
3. Clean the silicone from the transmission fluid pan and transaxle case surfaces thoroughly with
metal surface prep.
Installation
1. NOTE: Do not use more than the specified amount of sealer on the pan or internal transaxle
damage could occur.
Apply a bead 1.5 mm (0.06 in) thick of sealer to the transmission fluid pan.
2. Install the transmission fluid pan.
4. Fill the transaxle with clean transmission fluid.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Transmission Mode Indicator - A/T > Component Information > Description and Operation
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Halfshaft Seal - LH
Seals and Gaskets: Service and Repair Halfshaft Seal - LH
Halfshaft Seal - LH
Halfshaft Seal LH
Removal
1. Remove the front wheel and tire. For additional information, refer to Wheels and Tires.
2. Remove the LH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
3. Remove the halfshaft seal.
Installation
1. Using the Axle Oil Seal Installer and Handle, install the halfshaft seal.
System Information > Service and Repair > Halfshaft Seal - LH > Page 2927
2. Install the LH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
3. Install the front wheel and tire. For additional information, refer to Wheels and Tires.
4. Check the transmission fluid level and top off with transmission fluid, if necessary.
Seals and Gaskets: Service and Repair Halfshaft Seal - RH
Halfshaft Seal - RH
Halfshaft Seal RH
Removal
1. Remove the front wheel and tire. For additional information, refer to Wheels and Tires.
2. Remove the RH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
3. Remove the halfshaft seal.
Installation
1. Using the Output Shaft Seal Installer and Handle, install the halfshaft seal.
2. Install the RH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
3. Install the front wheel and tire. For additional information, refer to Wheels and Tires.
4. Check the transmission fluid level and top off with transmission fluid, if necessary.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

> Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position (BPP) Switch > Page
2935
strategy.
> Transmission Mode Switch, A/T > Component Information > Description and Operation

> Transmission Position Switch/Sensor, A/T > Component Information > Locations
> Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 2942
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
> Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
> Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page
2951
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor

> Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page
2954

> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor
Removal
Air Induction.

> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor >
Page 2957
Installation

Page 2958
Removal
- Remove the bolt.
Page 2959
Installation
2. Lower vehicle.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Shift Interlock: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
Component Information > Diagrams > Diagram Information and Instructions > Page 2964
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Shift Interlock: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Shift Interlock: Electrical Diagrams
37-1
can be found at Location Views. See:
Locations/Component Locations
Shift Interlock: Service and Repair
Brake Shift Interlock Override
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK
position, it is possible that a fuse has blown and the brake lights are not operational. Before driving
the vehicle, verify that the brake lights are working. This vehicle is equipped with a brake shift
interlock feature that prevents the selector lever from being moved out of PARK when the ignition is
in the ON or RUN position unless the brake pedal is pressed.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON
position and the brake pedal is pressed:
1. Apply the parking brake and remove the ignition key.
2. Remove the access panel.
3. Using a screwdriver or suitable tool, press the brake shift interlock override mechanism on the
selector lever, apply the brake, press the button on
the selector lever and move the selector lever into NEUTRAL.
4. Start the vehicle.
5. To install, reverse the procedure.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Shifter A/T: Diagrams
Information > Service and Repair > Selector Lever
Shifter A/T: Service and Repair Selector Lever
Selector Lever
Removal
2. Remove the selector lever cable from the selector lever.
1. Move the selector lever to the PARK position.
2. Remove the selector lever cable eyelet from the ball stud.
3. Squeeze the tabs and remove the selector lever cable from the selector lever assembly.
Information > Service and Repair > Selector Lever > Page 2995
3. Disconnect the selector lever assembly electrical connector.
4. Remove the 4 nuts and the selector lever assembly.
Installation
1. Install the selector lever assembly and the 4 nuts.
2. Connect the selector lever assembly electrical connector.
3. NOTE: The selector lever has its own detent mechanism. Holding the selector lever is not
necessary.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the
selector lever cable into the selector lever cable bracket and listen for the selector lever cable to
click in place. Pull back on the selector lever cable to make sure that it is locked into the selector
lever cable bracket. Also make sure that the selector lever cable end is correctly installed onto the
ball stud. Pull back on the selector lever cable end to make sure that the selector lever cable end is
correctly installed.
Install the selector lever cable on the selector lever.
1. Move the selector lever to the PARK position.
2. Install the selector lever cable in the selector lever assembly.
3. Install the selector lever cable eyelet on the ball stud.
4. Install the floor console. For additional information, refer to Instrument Cluster / Carrier &/or
5. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable
Adjustment See: Adjustments.
Shifter A/T: Service and Repair Selector Lever Knob
Selector Lever Knob
Removal
2. NOTE: Selector lever assembly removed for clarity.
Disconnect the Overdrive (O/D) switch electrical connector.
3. Remove the selector lever knob.
- Remove and discard the screw.
- Pull off the knob.
Installation
1. Position the selector lever knob onto the selector lever and route the wiring harness through the
selector lever bezel.
2. Slide the selector lever knob down the selector lever and install a new screw.
Connect the O/D switch electrical connector.
4. Install the floor console. For additional information, refer to Instrument Cluster / Carrier &/or
Shifter A/T: Service and Repair Selector Lever Bezel
Selector Lever Bezel
Removal
1. Remove the selector lever knob. For additional information, refer to Selector Lever Knob See:
Selector Lever Knob.
Remove the selector lever bezel.
- Unclip the bezel.
- Unclip the lamp.

Installation
Install the selector lever bezel.
- Clip in the lamp.
- Clip in the bezel.
2. Install the selector lever knob. For additional information, refer to Selector Lever Knob See:
Selector Lever Knob.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Service and Repair
Shift Cable: Service and Repair
Selector Lever Cable
Selector Lever Cable
Removal
3. Remove the Air Cleaner (ACL) and outlet pipe assembly. For additional information, refer to Fuel
4. NOTICE: Excessive bending of the flexible exhaust pipe may cause damage resulting in failure.
Support the flexible exhaust pipe with a
Cable, A/T > Component Information > Service and Repair > Page 3005
support wrap or suitable splint.
Support the flexible exhaust pipe, using a suitable wrap.
5. Disconnect the front exhaust pipe and detach the exhaust hanger isolators. Discard the gasket.
6. Disconnect the center exhaust hanger isolator and support the exhaust with wire.
7. Remove the 8 fasteners from and the exhaust heat shield.
8. Disconnect the selector lever cable from the retainer on the unibody.
9. Disconnect the selector lever cable from the selector lever cable bracket and manual control
lever.
1. Disconnect the selector lever cable end from the manual control lever.
2. Depress the tabs on the selector lever cable and remove the selector lever cable from the
selector lever cable bracket.
- Position the selector lever cable aside.

11. Remove the selector lever cable from the selector lever.
1. Shift the selector lever to PARK.
2. Unclip the selector lever cable.
3. Unclip the selector lever cable from the selector lever cable bracket.
12. Remove the heater core housing cover.
- Unclip the 4 clips.
- Remove the 2 screws.
13. NOTICE: When cutting the carpet, use care not to damage the heater core and evaporative
core housing.
Using a suitable tool, cut the carpet in the center under the heater core and evaporator core
housing to gain access to the selector lever cable grommet.
1. Begin cutting the carpet where the selector lever cable is exposed and cut the carpet back until
the tool no longer fits between the floor and the
heater core and evaporator core housing.
2. To cut the carpet further forward, access the carpet with the tool through the LH side of the
heater core and evaporator core housing. Cut the
carpet far enough forward to be able to position the carpet out from under the heater core and
evaporator core housing to access the selector lever cable grommet.
14. Position the carpet out from under the heater core and evaporator core housing to gain access
to the selector lever cable grommet.
15. NOTE: Heater core and evaporator core housing removed for clarity.
Remove the 2 selector lever cable grommet nuts.
16. Remove the selector lever cable.
- Pull the selector lever cable through the floor panel and remove it through the passenger
compartment.
Installation
1. NOTE: Heater core and evaporator core housing removed for clarity.
Position the selector lever cable in place, install the grommet on the floor panel and install the 2
nuts.
2. Position the carpet back in place under the heater core and evaporator core housing.
3. Install the heater core housing cover.
- Install the 4 clips.
- Install the 2 screws.
4. Attach the selector lever cable to the selector lever.
1. Shift the selector lever to PARK.
2. Clip the selector lever cable.
3. Clip the selector lever cable into the selector lever cable bracket.
5. Move the selector lever to the DRIVE position.
6. Move the manual control lever to the DRIVE position.
7. Unlock the selector lever cable end. Make sure that the selector lever cable end moves freely.
8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking
tabs are locked in place and the selector lever
cable end is snapped onto the ball stud. Press the selector lever cable into the selector lever cable
bracket and listen for the selector lever cable to click in place. Pull back on the selector lever cable
to make sure that it is locked into the selector lever cable bracket. Also make sure that the selector
lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable end to
make sure that the selector lever cable end is correctly installed.
Connect the selector lever cable end to the manual control lever.
1. Connect the selector lever cable to the selector lever cable bracket.
2. Connect the selector lever cable end to the manual control lever.
9. Press the lock tab down to secure the cable end from moving.
10. Install the selector lever cable in the retainer on the unibody.
11. Install the exhaust heat shield and the 8 fasteners.
12. Connect the center exhaust hanger isolator and remove the support wire.
13. NOTE: Install a new exhaust flange gasket.

Attach the exhaust hanger isolators and connect the front exhaust pipe.
14. Remove the support wrap.
15. Install the ACL and outlet pipe assembly. For additional information, refer to Fuel Delivery and
Air Induction.
16. NOTE: When the battery has been disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its
adaptive strategy. The vehicle may need to be driven to relearn the strategy.
Install the battery tray and battery.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Testing and Inspection > Torque Converter Diagnosis
Torque Converter: Testing and Inspection Torque Converter Diagnosis
Torque Converter Diagnosis
Prior to installing a new torque converter, all diagnostic procedures must be followed. This is to
prevent the unnecessary installation of new or remanufactured torque converters. Only after a
complete diagnostic evaluation can the decision be made to install a new torque converter.
Begin with the normal diagnostic procedures as follows:
1. Preliminary Inspection.
2. Know and Understand the Customer Concern.
3. Verify the Concern - Carry out the Torque Converter Operation Test; refer to Torque Converter
Operation Test.
4. Carry out Diagnostic Procedures. See: Transmission Control Systems/Testing and

Inspection/Initial Inspection and Diagnostic
Overview/Diagnostics
- Run On-Board Diagnostic (OBD) With Scan Tool, refer to Diagnostics See: Transmission Control
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostics. -
Repair all non-transaxle related DTCs first.
- Repair all transaxle DTCs.
- Rerun OBD to verify repair.
- Carry out the Line Pressure Test. Refer to Special Testing Procedures. See: Testing and
Inspection/Component Tests and General Diagnostics/Special Testing Procedures/Line Pressure
Test
- Carry out the Stall Speed Test. Refer to Special Testing Procedures. See: Testing and
Inspection/Component Tests and General Diagnostics/Special Testing Procedures/Stall Speed
Test
- Carry out the Diagnosis by Symptom Index. Refer to Diagnosis By Symptom See: Transmission
Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By
Symptom. -
Use the index to locate the appropriate routine that best describes the symptom(s). The routine will
list all possible components that may cause or contribute to the symptom. Check each component
listed; diagnose and repair as necessary before installing a new torque converter.
Torque Converter Operations Test
This test verifies that the Torque Converter Clutch (TCC) control system and the torque converter
are operating correctly.
1. Carry out the Self Test, see On-Board Diagnostic (OBD) With Scan Tool, refer to Diagnostics
See: Transmission Control Systems/Testing and
Inspection/Initial Inspection and Diagnostic Overview/Diagnostics. Check for DTCs. Refer to

Diagnostic Trouble Code (DTC) Charts See: Transmission Control Systems/Testing and
Inspection/Diagnostic Trouble Code Descriptions.
2. Monitor ECT, TFT and RPM PIDs.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for
approximately 15 minutes in Overdrive (O/D)
position.
4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80
km/h (50 mph) and tap the brake pedal with the left
foot.
5. The engine rpm should increase when brake pedal is tapped, and decrease about 5 seconds
after pedal is released. If this does not occur, see
Torque Converter Operation Concerns. Refer to Diagnosis By Symptom See: Transmission Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom.
Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 3015
6. If the vehicle stalls in O/D or D at idle with the vehicle at a stop, move the position selector lever
to manual 1 position. If the vehicle stalls, refer to
Torque Converter Operation Concerns in the Diagnosis By Symptom See: Transmission Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnosis By Symptom.
Repair as necessary. If the vehicle does not stall in O/D position, refer to Diagnosis By Symptom
See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic
Procedures/Diagnosis By Symptom.
Component Information > Testing and Inspection > Torque Converter Diagnosis > Page 3016
Torque Converter: Testing and Inspection Torque Converter Contamination Inspection
Torque Converter Contamination Inspection
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
- A torque converter malfunction has been determined based on complete diagnostic procedures.
- The torque converter stud or studs, impeller hub or bushing are damaged.
- The torque converter exhibits external discoloration (due to overheating).
- There is evidence of transmission assembly or fluid contamination due to the following

transmission or converter failure modes. -
Major metallic failure
- Multiple clutch plates or band failures
- Sufficient component wear which results in metallic contamination
- Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white
tissue or through a paper filter.
4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red
in color and not have a burnt smell.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
- drain the remaining fluid from the torque converter.
- using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter
and agitate by hand.
- thoroughly drain the fluid.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Specifications > Mechanical Specifications
Transmission Cooler: Mechanical Specifications

Component Information > Specifications > Mechanical Specifications > Page 3021
Transmission Cooler: Fluid Type Specifications

Transmission Cooler: Description and Operation
Transaxle Cooling
The transmission fluid cooling system consists of the following:
- Oil-To-Air (OTA) transmission fluid combo cooler
- Transmission fluid cooler tube assembly
- Transmission fluid cooler inlet tube
- Transmission fluid cooler outlet tube
This vehicle is equipped with an external transmission fluid cooler. The transmission fluid cooler is
attached to the front of the A/C condenser and can be serviced separately. Transmission fluid
travels from the transaxle through the upper transmission fluid cooler tube, into the transmission
fluid cooler, through the transmission fluid cooler, out of the transmission fluid cooler, through the
lower transmission fluid cooler tube and back into the transaxle. The transmission fluid cooler
transfers heat from the transmission fluid to the outside air.
Transaxle Cooling
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Transmission Cooler: Initial Inspection and Diagnostic Overview
Transaxle Cooling
Transaxle Cooling
1. Verify the customer concern by operating the vehicle to duplicate the condition.
2. If the inspection reveals obvious concern(s) that can be readily identified, repair as necessary.
3. Install new components if a transmission fluid leak is found in any of the transaxle cooling
components.
4. If the concern(s) remains after the inspection, determine the symptom(s). GO to Symptom Chart
- Transaxle Cooling or GO to Symptom Chart -
NVH. See: Symptom Related Diagnostic Procedures/Symptom Chart - Transaxle Cooling See:
Symptom Related Diagnostic Procedures/Symptom Chart - NVH
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3025
Transmission Cooler: Symptom Related Diagnostic Procedures
Symptom Chart - Transaxle Cooling
Transaxle Cooling
Symptom Chart - Transaxle Cooling
Symptom Chart - NVH
Transaxle Cooling
Symptom Chart - NVH

Transmission Cooler: Component Tests and General Diagnostics
4F27E
Transmission Fluid Cooler
NOTICE: Whenever the transaxle has been disassembled to install new parts, clean and backflush
the transmission fluid cooler or contaminants in the transaxle cooling system can cause failure of
the transaxle.
NOTE: Cleaning and backflushing the transmission fluid cooling system along with normal cleaning
and inspection procedures as outlined during disassembly and reassembly will keep contamination
from reentering the transaxle and causing a repeat repair.
When internal wear or damage has occurred in the transaxle, metal particles, clutch plate material
or band material may have been carried into the torque converter and transmission fluid cooler.
These contaminants are a major cause of recurring transaxle troubles and must be removed from
the system before the transaxle is put back in use.
Transmission Fluid Cooler Flow Test
NOTE: The selector lever linkage adjustment, transmission fluid level and line pressure must be
within specification before carrying out this test. Refer to Automatic Transmission/Transaxle for
selector lever linkage adjustment procedure. For transmission fluid level checking procedures, refer
to Preliminary Inspection See: Transmission Control Systems/Testing and Inspection/Initial
Inspection and Diagnostic Overview/Preliminary Inspection. For transaxle line pressure testing,
refer to Special Testing Procedures See: Testing and Inspection/Component Tests and General
Diagnostics/Special Testing Procedures.
1. Check the transmission fluid level and fill as necessary.
2. Remove the transmission fluid level indicator from the transaxle filler tube and install a funnel in
the transaxle filler tube.
3. With the vehicle in NEUTRAL, position it on a hoist. Refer to Vehicle Jacking and Lifting. Inspect
the transmission fluid cooler tubes for damage.
Install new transmission fluid cooler tubes as needed.
4. Disconnect the transmission fluid cooler return hose from the transmission fluid cooler return
tube.
5. Plug the transmission fluid cooler return hose to avoid transmission fluid loss.
6. Connect one end of a hose to the cooler return tube and route the other end of the hose up to a
point where it can be inserted into the funnel at the
transaxle filler tube.
7. Start the engine and run at idle with the transaxle in NEUTRAL range until the transmission fluid
is warm. Temperature is important to the flow
rate measurement. -
Once the transmission fluid flow no longer has air bubbles in it, remove the rubber hose from the
funnel and insert it into a liter container. As soon as 0.95L (1 qt) is dispensed into the container,
install the hose into the funnel. One quart of transmission fluid should flow through the cooling
system in approximately 17-21 seconds.
8. Once adequate flow is determined, shut off the engine, remove the extension hose and reinstall
the transmission fluid cooler tubes with the
constant tension clamp.
9. If flow is not adequate, stop the engine. Disconnect the hose from the transmission fluid cooler
return tube and connect it to the converter-out tube.
If flow is now liberal, install a new transmission fluid cooler. Refer to Transmission Cooler, A/T.
10. Check the transmission fluid level and adjust as required.
Transmission Fluid Cooler Tube Replacement
Refer to Transmission Cooler, A/T.

Transaxle Cooling
Transaxle Cooling
Check Transmission Fluid Level and Condition
NOTICE: The vehicle should not be driven if the transmission fluid level is below the bottom line on
the transmission fluid level indicator and the ambient temperature is above 10°C (50°F).
NOTICE: Incorrect transmission fluid level may affect the transaxle operation and could result in
transaxle damage.
NOTE: Transmission fluid expands when warmed. To obtain an accurate transmission fluid level,
drive the vehicle approximately 30 km (18.75 mi) until normal operating temperature is reached.
NOTE: If the vehicle has been operated for an extended period at high speeds, in city traffic, during
hot weather or while pulling a trailer, the vehicle should be turned OFF for approximately 30
minutes to allow the transmission fluid to cool before checking.
The transmission fluid level reading on the transmission fluid level indicator will differ depending on
operating and ambient temperatures. The correct reading should be within the normal operating
temperature range.
Transmission Fluid Level Check
NOTE: The transmission fluid should be checked at normal operating temperature 49°C-60°C
(120°F-140°F) on a level surface. Normal operating temperature can be reached after
approximately 32 km (20 mi) of driving and can be checked using the scan tool.
Under normal circumstances the transmission fluid level should be checked during normal
maintenance. If the transaxle starts to slip, shifts slowly or shows signs of transmission fluid
leaking, the transmission fluid level should be checked.
1. Drive the vehicle 30 km (18.75 mi) or until the vehicle reaches normal operating temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With foot on the brake, start the engine and move the selector lever through all the gear ranges.
Allow sufficient time for each gear to engage.
4. Place the selector lever in PARK and leave the engine running.
5. Remove the transmission fluid level indicator and wipe it clean with a lint free cloth.
6. Install the transmission fluid level indicator, making sure that it is fully seated in the transaxle
filler tube.
7. Remove the transmission fluid level indicator. The transmission fluid should be within the
designated areas.
High Transmission Fluid Level
A transmission fluid level that is too high may cause the transmission fluid to become aerated due
to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming,
loss of transmission fluid from the vent tube and possible transaxle malfunction and/or damage. If
an overfill reading is indicated, refer to Automatic Transmission/Transaxle &/or Transmission
Control Systems.
Low Transmission Fluid Level

A low transmission fluid level could result in poor transaxle engagement, slipping, malfunction
and/or damage. This could also indicate a leak in one of the transaxle seals or gaskets.
Adding Transmission Fluid
NOTICE: Automatic transmission fluids are not interchangeable. The use of any transmission fluid
other than what is recommended for this transaxle will cause transaxle damage.
If transmission fluid needs to be added, add transmission fluid in 0.25L (1/2 pt) increments through
the transaxle filler tube. Do not overfill the transmission fluid. For transmission fluid type, refer to
the Material chart.
Transmission Fluid Condition Check
2. Observe the color and the odor. The color under normal circumstances should be a dark red
color, not brown or black or have a burnt odor.
3. Hold the transmission fluid level indicator over a white facial tissue and allow the transmission
fluid to drip onto the facial tissue and examine the
stain.
4. If evidence of solid material is found, the transmission fluid pan should be removed for further
inspection.
5. If transmission fluid contamination or transaxle failure is confirmed by the sediment in the bottom
of the transmission fluid pan, repair the
transaxle and clean the transmission fluid cooler tubes and transmission fluid cooler.
6. If the transaxle is to be overhauled or if installing a new transaxle, the transmission fluid cooler
must be backflushed. Refer to Automatic
Transmission/Transaxle &/or Transmission Control Systems.

Transmission Cooler: Procedures
Cooler, A/T.
reservoir.

Transmission Cooler: Removal and Replacement
Removal
2. Remove the front bumper cover. For additional information, refer to Bumper.
3. Position the wiring harness aside.

4. Disconnect the transmission fluid cooler tubes from the transmission fluid cooler.
- Compress the tabs on the transmission fluid cooler tubes and slide the latch out of the
transmission fluid cooler tube to unlock the transmission fluid cooler tube from the transmission
fluid cooler.
5. Remove the transmission fluid cooler from the transmission fluid cooler bracket.
6. Remove the transmission fluid cooler.
Installation
1. Position the transmission fluid cooler in place.
2. Install the transmission fluid cooler onto the transmission fluid cooler bracket.
3. NOTE: If the transmission fluid cooler tube latches are not in the unlocked position, compress
the tabs on the transmission fluid cooler tube
latches and slide the latch out of the transmission fluid cooler tube to unlock the latch.
Connect the transmission fluid cooler tubes to the transmission fluid cooler.
4. Position the wiring harness in place.
5. Install the front bumper cover. For additional information, refer to Bumper.
6. Fill the transmission with the specified transmission fluid.
7. Check transmission for correct operation and/or leaks. Repair as needed.
Transmission Fluid Cooler Tubes

Removal
3. Disconnect the transmission fluid cooler tubes from the transmission.
fluid cooler.
4. Position the wiring harness aside.
5. Disconnect the transmission fluid cooler tubes from the transmission fluid cooler.
fluid cooler.
6. Remove the transmission fluid cooler tubes.
Installation
1. Position the transmission fluid cooler tubes in place.
Connect the transmission fluid cooler tubes to the transmission fluid cooler.
Connect the transmission fluid cooler tubes to the transmission.

4. Position the wiring harness in place.
5. Install the front bumper cover. For additional information, refer to Bumper.
6. Fill the transmission with the specified transmission fluid.
7. Check transmission for correct operation and/or leaks. Repair as needed.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Indicator - A/T > Component Information > Description and Operation
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Service and Repair > Transaxle Support Insulator
Transmission Mount: Service and Repair Transaxle Support Insulator
Transaxle Support Insulator
Transaxle Support Insulator
Removal
2. Install the Engine Support Bar, Engine Lifting Bracket and Adapters and support the engine.
Component Information > Service and Repair > Transaxle Support Insulator > Page 3049
3. Remove the transaxle support insulator nuts and remove the transaxle support insulator.
Installation
1. Install the transaxle support insulator nuts.
- Install the 4 transaxle support insulator-to-body nuts. -
Tighten to 48 Nm (35 lb-ft).
- Install the transaxle support insulator-to-bracket nut. -
2. Remove the Engine Support Bar, Engine Lifting Bracket and Adapters and support the engine.
3. Install the battery tray and battery. For additional information, refer to Battery.
Transmission Mount: Service and Repair Transaxle Support Insulator - Anti-Roll
Transaxle Support Insulator - Anti-Roll
Removal
2. Remove the 2 bolts and the nut, rotate the bottom of the engine forward enough so the roll
restrictor clears the subframe and remove the roll
restrictor.
Installation
1. NOTICE: The roll restrictor bolts are different lengths. If the long bolt is used to hold the roll
restrictor to the subframe, damage to the
steering rack may occur.
Position the roll restrictor in place and loosely install the roll restrictor-to-subframe bolt.
2. Install the roll restrictor-to-transaxle bracket bolt and tighten both of the roll restrictor bolts.

Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor
Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS) Sensor > Page 3064
Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor

Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS) Sensor > Page 3067

Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor
Removal
Air Induction.

Sensor, A/T > Component Information > Service and Repair > Turbine Shaft Speed (TSS) Sensor > Page 3070
Installation

Removal
- Remove the bolt.
Installation
2. Lower vehicle.
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Valve Body: Service and Repair
Main Control
Removal
1. Remove the transmission fluid pan. For additional information, refer to Transmission Fluid Pan
See: Fluid Pan/Service and Repair.
2. Disconnect the Transmission Fluid Temperature (TFT) sensor electrical connector.
3. Remove the transmission fluid filter.
4. NOTE: It is necessary to note the location of the main control wire harness connectors so they
can be connected in the same positions. Connector
color letters are cast into the solenoid body.
Remove the main control ground wire bolt. Disconnect the electrical connectors and remove the
main control wiring harness.
1. Shift Solenoid C (SSC), color N (white).
2. Shift Solenoid E (SSE), color G (green).
3. Shift Solenoid D (SSD), color L (blue).
4. Line Pressure Control (LPC), color B (black).
5. Shift Solenoid A (SSA), color N (neutral).
6. Shift Solenoid B (SSB), color B (black).
5. NOTE: Note the locations of the 2 long bolts.
Remove the main control valve body and accumulators.

6. NOTE: Each accumulator is equipped with 2 springs. All 4 springs are different sizes.
NOTE: Note the size and location of the accumulator springs to aid assembly.
NOTE: Note the shape of each piston and the piston bore from which the piston was removed. The
shape and size will vary depending on application. The piston must be installed in its correct bore
during assembly.
Remove the accumulator pistons and springs.
Installation
1. NOTE: The thin longer springs are for the neutral and drive accumulator.
NOTE: Accumulator bore and pistons are matched by depth; some pistons may have steps. Install
the pistons in the same bore as removed.
Install the accumulator pistons and springs.
1. Accumulator 1 and 2.
2. Accumulator N and D.
2. NOTICE: Make sure that the manual control valve lever is in the manual control valve or the
transaxle will not shift between gear
positions correctly.
NOTE: Do not fully tighten the main control valve bolts at this stage.
Install the main control valve body.
3. Tighten the main control valve body bolts.
- Tighten the bolts in the sequence shown. -

4. NOTE: It is necessary to connect the electrical connectors in the same positions as noted in
disassembly. Connector color letters are cast into the
solenoid body.
Install the main control valve wiring harness, connect the electrical connectors and install the main
control ground wire bolt.
1. SSC, color N (white).
2. SSE, color G (green).
3. SSD, color L (blue).
4. LPC, color B (black).
5. SSA, color N (neutral).
6. SSB, color B (black).
5. Install the transmission fluid filter.
6. Connect the TFT sensor electrical connector.
7. Install the transmission fluid pan. For additional information, refer to Transmission Fluid Pan
See: Fluid Pan/Service and Repair.
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Application and
ID
Differential Assembly: Application and ID
Driveline System
The driveline system consists of the following:
- Right halfshaft with inner and outer CV joint
- Left halfshaft with inner and outer CV joint
- Intermediate shaft connecting the transaxle to the right halfshaft
- Intermediate shaft bearing that supports the inner right halfshaft CV joint
- Circlips that retain the intermediate shaft and left halfshaft inner CV joint in the transaxle
differential side gears
- Splined outer CV joints that mesh with the front drive hubs
- Outboard CV joint wheel hub nuts that secure the CV joints to the wheel hubs
The transaxle contains the differential assembly. The differential receives torque directly from the
transmission. Inside the differential, side gears are splined to the right inboard CV joint and
intermediate shaft. The differential allows the halfshaft and intermediate shaft to be driven at
different speeds as required, such as when cornering. The rotational direction of the halfshafts
determines the vehicle movement. The articulation of the front wheels, both in steering and normal
jounce and rebound, is controlled by the CV joint. Both plunge and multi-ball style CV joints are
used. The CV joints are permanently lubricated with a special high temperature grease and require
no periodic maintenance.
Halfshaft Handling
NOTICE: Excessive pulling force on the interconnecting shaft between the joints of the halfshaft will
result in internal joint damage and separation. Axial loads used in assisting removal should be
applied through the inboard joint housing only. Handle the halfshaft only by the interconnecting
shaft to avoid pull-apart and potential damage to the Constant Velocity (CV) joints. Do not
over-angle the CV joints. Damage will occur to an assembled inner CV joint if it is over-plunged
outward from the joint housing.
NOTE: Never use the halfshaft assembly as a lever to position other components. Always support
the free-end of the halfshaft. Do not allow the boots to contact sharp edges or hot exhaust
components.
Handle all halfshaft components carefully during removal and installation procedures.
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Application and
ID > Page 3081
Differential Assembly: Description and Operation
Driveline System
Halfshaft Handling
components.
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview
Differential Assembly: Initial Inspection and Diagnostic Overview
Principals Of Operation
Driveline System
Principals of Operation
Driveline System - General Information
The driveline system enables the power generated by the engine and transferred through the
transaxle to place the vehicle in motion. Rotational torque received from the transaxle is delivered
to the front wheels by halfshafts. The CV joints at the ends of the shafts allow the shafts to rotate
smoothly in an allowable angle plane. The rotational torque is introduced into the differential ring
gear which drives the differential. The differential divides the torque between the left and right axle
shafts, while permitting the shafts to turn at different speeds when required, such as when
cornering.
Driveline System
2. Visually inspect for obvious signs of mechanical 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. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - NVH. See:
Symptom Related Diagnostic Procedures
Intermediate Shaft Support Bearing
With the vehicle in NEUTRAL, position it on a hoist. Refer to Vehicle Jacking and Lifting. Rotate the
intermediate shaft by hand. If the support bearing shows any signs of roughness or wear, install a
new intermediate shaft bearing. Refer to Drive Axles, Bearings and Joints.
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 3084
Differential Assembly: Symptom Related Diagnostic Procedures
Driveline System
Symptom Chart - NVH

Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Constant Velocity (CV) Joint Boot
Constant Velocity Joint Boot: Service and Repair Inner Constant Velocity (CV) Joint Boot
Inner Constant Velocity (CV) Joint Boot
Removal
1. Remove the halfshaft. For additional information, refer to Halfshaft - LH See: Service and
Repair/Halfshaft - LH or Halfshaft - RH See: Service
and Repair/Halfshaft - RH.
2. Secure the halfshaft in a soft-jawed vise.
- Cut, remove and discard the inner CV joint boot clamps.
- Remove the inner CV joint housing.
3. Remove and discard the tripod circlip.
4. Using a suitable 3 jaw puller, remove the tripod.
- Remove and discard the CV joint boot.

Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Constant Velocity (CV) Joint Boot >
Page 3091
Installation
1. NOTICE: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The
outer joint must not be bent more than 45
degrees or damage to the joint may occur.
Install a new CV joint boot.
2. Using the Constant Velocity Joint Boot Clamp Installer, install the new CV joint boot inner clamp.
3. NOTICE: Use care not to damage the Constant Velocity (CV) joint bearings or component
damage may occur.
Using a suitable installer, install the tripod.
4. Install the new tripod circlip.
5. Apply grease (130 g [4.58 oz] provided with the boot kit) into the CV joint housing and boot.
6. Position the tripod in the housing in the following sequence.
1. Install the tripod into the bottom of the CV joint housing.
2. Position the outer boot clamp on the boot.
7. NOTICE: Use care not to damage the boot or component damage may occur.
Install the front halfshaft.
1. Insert a small screwdriver under the boot seat to allow the air to escape.
2. Slide the tripod joint in as far as possible, then pull it out 20 mm (0.787 in).
- Remove the screwdriver.

Page 3092
8. Using the Constant Velocity Joint Boot Clamp Installer, install the new outer boot clamp.
9. Install the halfshaft. For additional information, refer to Halfshaft - LH See: Service and
Repair/Halfshaft - LH or Halfshaft - RH See: Service
and Repair/Halfshaft - RH.

Page 3093
Constant Velocity Joint Boot: Service and Repair Outer Constant Velocity (CV) Joint Boot
Outer Constant Velocity (CV) Joint Boot
Removal
1. Remove the inner CV boot. For additional information, refer to Inner Constant Velocity (CV) Joint
Boot See: Inner Constant Velocity (CV) Joint
Boot.
2. NOTICE: Use a vise with protective jaw covers or damage to the halfshaft may occur.
Remove the outer CV joint boot.
- Cut, remove and discard the boot clamps.
- Pull the boot inward over the halfshaft.
Installation
1. Apply grease (125 g [4.40 oz] provided with the boot kit) into the CV joint and boot.
2. NOTICE: Use care not to damage the boot or component damage may occur.
Install the outer CV joint boot.
- Slide the outer boot outward over the CV joint.
- Press the boot into the annular groove on the CV joint.
- Slide a small screwdriver under the boot seat to allow the air to escape.
- Locate the boot in position and remove the screwdriver.

Page 3094
3. Using the Constant Velocity Joint Boot Clamp Installer, install the new boot clamps.
4. Install the inner CV boot. For additional information, refer to Inner Constant Velocity (CV) Joint
Boot See: Inner Constant Velocity (CV) Joint
Boot.
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Front Suspension

Information > Service and Repair > Front Suspension > Page 3099
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and
wheel hub.
Installation
wheel hub.
4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering and


Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >

to..............................................................................................................................................340 Nm
(251 lb-ft).

Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Component
Drive/Propeller Shafts, Bearings and Joints: Description and Operation
Driveline System
Halfshaft Handling
components.
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Install the flexplate or flywheel and the 6 bolts. Tighten the bolts in the sequence shown in 3
stages: Stage 1: Tighten to...................................................................................................................
......................................................................50 Nm (37 lb-ft). Stage 2: Tighten to..............................
...........................................................................................................................................................8
0 Nm (50 lb-ft). Stage 3: Tighten to......................................................................................................
.................................................................................112 Nm (83 lb-ft).
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
3112
Flex Plate: Testing and Inspection
Flexplate Inspection
1. Inspect the flexplate for:
1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.

Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair >
Procedures
Flex Plate: Procedures
Flexplate Inspection
1. Inspect the flexplate for:
1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.

Flex Plate: Removal and Replacement
Exploded View - Flexplate and Crankshaft Rear Seal With Retainer Plate
Flexplate and Crankshaft Rear Seal With Retainer Plate
Flexplate
Flexplate
Removal
2. Remove the transaxle. For additional information, refer to Automatic Transmission/Transaxle

&/or Transmission Control Systems.
3. Install the Flywheel Holding Tool and remove the 6 flexplate bolts and the flexplate. Discard the
bolts.
Installation
1. NOTE: Special bolts are used for installation. Do not use standard bolts.
Install the flexplate.
2. Install the Flywheel Holding Tool.
3. Tighten the new bolts in the sequence shown in 3 stages:
4. Install the transaxle. For additional information, refer to Automatic Transmission/Transaxle &/or
Transmission Control Systems.
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation
Ford Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Component Information > Description and
Operation
Power Take-Off: Description and Operation
Power Take-Off (PTO) Switch and Circuits
The PTO circuit is used by the PCM to disable some of the OBD monitors during PTO operation.
The PTO switch is normally open. When the PTO unit is activated, the PTO switch is closed and
battery voltage is supplied to the PTO input circuit. This indicates to the PCM that an additional
load is being applied to the engine. The PTO indicator lamp illuminates when the PTO system is
functioning correctly and flashes when the PTO system is damaged.
When the PTO unit is activated, the PCM disables some OBD monitors which may not function
reliably during PTO operation. Without the PTO circuit information to the PCM, false DTCs may be
set during PTO operation. Prior to an inspection/maintenance (I/M) test, operate the vehicle with
the PTO disengaged long enough to successfully complete the OBD monitors.
PTO Circuits Description
The 3 PTO input circuits are PTO mode, PTO engage, and PTO RPM.
The PTO engage circuit is used when the operator is requesting the PCM to check the needed
inputs required to initiate the PTO engagement.
The PTO RPM circuit is used when the operator is requesting additional engine RPM for PTO
operation.
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position
(BPP) Switch
follows: -
Typical BPP Switch

and Switches - A/T > Brake Switch - TCC > Component Information > Description and Operation > Brake Pedal Position
(BPP) Switch > Page 3131
strategy.
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation

and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3138
Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Output Shaft Speed (OSS)
Sensor > Page 3147
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS)
Sensor

and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed (OSS)
Sensor > Page 3150

and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Turbine Shaft
Speed (TSS) Sensor
Removal
Air Induction.

Speed (TSS) Sensor > Page 3153
Installation

Removal
- Remove the bolt.
Installation
2. Lower vehicle.
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams

Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators -
Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches -
and Operation > Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

and Operation > Brake Pedal Position (BPP) Switch > Page 3173
strategy.
Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >

Removal
cable.

Installation
bolts.
1. "1" M1
2. "2" M2
3. "D" Drive
4. "N" Neutral
5. "R" Reverse
6. "P" Park
sensor.
Locations > Output Shaft Speed (OSS) Sensor
Locations > Output Shaft Speed (OSS) Sensor > Page 3189
Diagrams > Output Shaft Speed (OSS) Sensor

Diagrams > Output Shaft Speed (OSS) Sensor > Page 3192

Service and Repair > Turbine Shaft Speed (TSS) Sensor
Removal
Air Induction.

Installation

Removal
- Remove the bolt.
Installation
2. Lower vehicle.
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Sensor Block >

Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
cluster.

Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 3215
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 3221
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer

Unit (HCU) See: Hydraulic Control Assembly
- Antilock Brakes/Service and Repair.

Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)

Assembly - Antilock Brakes > Component Information > Service and Repair > Page 3230

injury.
water.
1. NOTE: This step is only necessary if a new ABS module is being installed on a vehicle equipped
with AdvanceTrac(R).
Connect the scan tool and upload the module configuration from the ABS module.
2. Remove the Air Cleaner (ACL). For additional information, refer to Fuel Delivery and Air
Induction.
3. Remove the brake fluid reservoir cap and using a suitable clean suction device, remove the
brake fluid from the brake fluid remote reservoir.
4. Remove the transaxle support insulator. For additional information, refer to Automatic
Transmission/Transaxle &/or Transmission Control
Systems.
5. Disconnect the PCM electrical connectors.
6. Detach the wiring harness retaining clips from the PCM bracket.
7. Remove the 3 bolts and the ACL bracket with the PCM bracket and PCM attached.
8. Remove the ground cable bolt and position the cable aside.

11. Disconnect the ABS module electrical connector by rotating the connector.
12. NOTE: Cap the brake tube connections to prevent fluid loss or dirt contamination.
NOTE: To aid in correct installation, make a note of the position of the brake tubes.
Remove the master cylinder-to-Hydraulic Control Unit (HCU) brake tubes.
Disconnect the remaining brake tubes and position aside.
- To install, tighten the LF and RR brake tube fittings to 23 Nm (17 lb-ft).
- To install, tighten the RF and LR brake tube fittings to 20 Nm (177 lb-in).
14. Remove the LF brake tube from the retaining clip on the LH inner frame rail.
15. Remove the 3 HCU bracket-to-frame nuts and remove the HCU and bracket assembly from the
vehicle.

16. Remove the 2 HCU-to-bracket bolts and separate the HCU from the support bracket.
1. If a new ABS module was installed on a vehicle equipped with AdvanceTrac(R) with Roll Stability
Control (RSC(R)), download the module
configuration information from the scan tool. For additional information, refer to Information Bus.
2. If a new ABS module or HCU was installed on a vehicle equipped with AdvanceTrac(R) with
RSC(R), carry out the IVD Initialization
sequence for all 4 stability control sensors (roll rate, yaw rate, lateral acceleration, longitudinal
acceleration), the steering angle sensor and the brake fluid pressure sensor. Follow the scan tool
directions.
3. Bleed the brake system. For additional information, refer to Brakes and Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair
Removal
Installation

procedure.

Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Service and Repair > Page 3236
directions.
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front


Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front

clips.

Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3253
clips.
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Component Bleeding
Component Bleeding
Master Cylinder
injury.
water.
Component Bleeding > Page 3258
damaged.
fluid.
bubbles.

System Bleeding.
Brake Caliper
injury.
water.
screw. -
Wheel Cylinder
injury.
water.
screw. -

Pressure Bleeding
injury.
water.
bleeding operation.
Specifications.
Manual Bleeding
injury.
water.
bleeder screw. -
bleeder screw. -

Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
Brake Pedal Assy: Service and Repair

Brake Pedal and Bracket
1. Remove the lower steering column cover. For additional information, refer to Instrument Panel -
Exploded View in Instrument Cluster / Carrier
&/or Interior Moulding / Trim.
2. 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.
3. Remove the brake booster actuating rod from the brake pedal in the following sequence.
1. Disengage the tabs.
2. Remove and discard the brake booster actuating rod pin.
4. Remove the brake pedal retractor bolt.
5. Remove the 4 brake booster nuts.
6. Remove the brake pedal bracket.

Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Page 3267
7. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This 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 this switch with the brake pedal in any other position will result in incorrect adjustment
and may damage the switch.
- Install a new brake booster actuating rod pin.

Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Brake Caliper
Brake Caliper: Service and Repair Brake Caliper
Brake Caliper
injury.
water.
2. Remove the brake pad anti-rattle spring.
3. Disconnect the brake flexible hose fitting from the brake caliper.
4. Remove the 2 guide pin bolt covers, the 2 brake caliper guide pin bolts and remove the brake
caliper.
- To install, tighten the bolts to 30 Nm (22 lb-ft).
- Apply silicone grease to the brake pad-to-brake caliper contact points.
- Make sure the holding feature on the brake flexible hose is aligned with the notch on the brake
caliper.
- Bleed the brake caliper. For additional information, refer to Component Bleeding in Brakes and
Traction Control.
Service and Repair > Brake Caliper > Page 3273
Brake Caliper: Service and Repair Disc Brake System - Exploded View
Disc Brake System - Exploded View
Service and Repair > Brake Caliper > Page 3274
Brake Caliper: Service and Repair Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
1. Remove the brake pads. For additional information, refer to Brake Pads See: Brake Pad/Service
and Repair/Brake Pads.
2. Remove the 2 bolts and the brake caliper anchor plate.
- Apply brakes several times to verify correct brake operation.

Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest for Brake Pad: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear
Prematurely
Brake Pad: Customer Interest Brakes - Front Brake Pads Wear Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Technical Service Bulletins > Customer Interest for Brake Pad: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear
Prematurely > Page 3283
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 11-2-11 > Feb > 11 > Brakes - Front Brake
Pads Wear Prematurely
Brake Pad: All Technical Service Bulletins Brakes - Front Brake Pads Wear Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 11-2-11 > Feb > 11 > Brakes - Front Brake
Pads Wear Prematurely > Page 3289
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Technical Service Bulletins > Page 3290
Brake Pad: Specifications
Brake Pad minimum Thickness............................................................................................................

........................................................2.0 mm (0.078 in)
Service and Repair > Disc Brake System - Exploded View
Brake Pad: Service and Repair Disc Brake System - Exploded View
Service and Repair > Disc Brake System - Exploded View > Page 3293
Brake Pad: Service and Repair Brake Pads
Brake Pads
injury.
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
water.
1. Check the brake fluid level in the brake master cylinder remote reservoir.
- If required, remove the fluid until the brake master cylinder reservoir is half full.
4. 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 caliper flexible hose or damage to
the hose may occur.
Remove the 2 guide pin bolt covers, the 2 brake caliper guide pin bolts and position the caliper
aside.
- Support the caliper using mechanic's wire.

5. Remove the 2 brake pads.
6. NOTICE: Protect the caliper pistons and boots when pushing the caliper pistons into the caliper
piston bores or damage to components
may occur.
If installing new brake pads, using a C-clamp and a worn brake pad, compress the disc brake
caliper pistons into the caliper.
- Fill master cylinder reservoir with specified brake fluid.

Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications
Brake Rotor/Disc: Specifications
Front Brake Disc minimum thickness...................................................................................................

......................................................21.5 mm (0.846 in)
> Service and Repair > Procedures
Brake Rotor/Disc: Procedures
Brake Disc Machining
NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only.
Read the entire operating manual and/or view the video shipped with the lathe before installing,
operating or repairing the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred.
However, if the lathe is not self adjusting, the lathe oscillation must be adjusted using a dial
indicator. The total indicated runout target is 0.000 mm (0.000 in). The maximum indicated runout
should be no more than 0.050 mm (0.002 in). If the runout adjustment (automatic or manual) is
carried out correctly prior to machining, then the final brake disc runout will be within specification,
and a runout measurement is not necessary after machining.
NOTE: Do not machine new brake discs.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct
adjustment of the on-vehicle brake lathe will make sure that these dimensions are within
specifications.
2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
NOTE: It is not necessary to disconnect the brake tube from the brake caliper.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside,
as required.
- Support the brake caliper using mechanic's wire.
3. Install the hub adapter using:
- four wheel nuts on a 4-stud wheel hub.
- five wheel nuts on a 5-stud wheel hub.
- six wheel nuts on a 6-stud wheel hub.
- four wheel nuts on a 7- or 8-stud wheel hub.
- five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total
indicated runout target is 0.000 mm (0.000 in). The
maximum indicated runout should be no more than 0.050 mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter
cuts will cause the bit to heat up and wear faster.
Heavier cuts will cause poor brake disc surface finish.
Machine the brake disc.

8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
11. Measure the brake disc thickness.
- If the measurement is below the minimum specification, install a new brake disc. For additional
information, refer to Disc Brake System.
12. NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications.
Position the brake caliper or brake caliper and anchor plate assembly.
- Install the bolts.

> Service and Repair > Procedures > Page 3299
- For fastener torque specifications, refer to Disc Brake System.
13. Install the wheel and tire. For additional information, refer to Wheels and Tires.
> Service and Repair > Procedures > Page 3300
Brake Rotor/Disc: Removal and Replacement

Brake Disc
Brake Disc
2. NOTICE: Do not allow the caliper to hang by the brake hose or damage to the hose can occur.
Remove the 2 brake caliper anchor plate bolts and position the brake caliper and anchor plate
assembly aside.
- Support the brake caliper and anchor plate assembly using mechanic's wire.
3. If equipped, remove the brake disc retaining washer.
- Remove the brake disc.

Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information >
Service and Repair
Backing Plate: Service and Repair
Brake Backing Plate
1. Remove the brake shoes. For additional information, refer to Brake Shoes See: Brake
Shoe/Service and Repair.
2. Remove the wheel cylinder. For additional information, refer to Wheel Cylinder See: Wheel
Cylinder/Service and Repair.
3. Remove the spindle. For additional information, refer to Rear Suspension.
4. Compress the parking brake cable conduit locking tabs and pull the parking brake cable
assembly through the backing plate.
5. If equipped, drill out the 2 rivets and remove the backing plate.
- It is not necessary to install new rivets.

Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Customer Interest: > 10-15-3 > Aug > 10 > Brakes - Rear Brake Thumping/Knocking Noise
Brake Drum: Customer Interest Brakes - Rear Brake Thumping/Knocking Noise
TSB 10-15-3
08/16/10
THUMPING/KNOCKING NOISE - REAR BRAKES
This article supersedes TSB 09-19-14 to update the Service Procedure.
ISSUE Some 2010 Transit Connect vehicles may exhibit a thumping or knocking noise coming
from the rear when braking. The cause of the noise (at low mileage) may be the screw effect of the
rear drum inner friction sur[ace during initial braking, when rear shoes first touch the drum. When
new rear shoes initially touch a new drum inner surface, on some vehicles, there is tendency for
the shoes to follow the turning marks (directional grooves in the sur[ace finish), move laterally and
hit the backing plate in each wheel rotation. This can cause a repeating knock-knock noise. This
noise will continue until bedding occurs between the rear shoes and drum (swapping the drums
changes the direction of the grooves). After bedding occurs, the turning marks on the drum surface
disappear.
SERVICE PROCEDURE
1. Apply the parking brake 3 notches.
2. Drive the vehicle at a maximum of 15 mph (24 Km/h) in first gear for 820 feet (250 meters).
3. Drive vehicle for 820 feet (250 meters) in reverse.
4. Release parking brake and wait a minimum of 15 minutes.
5. Road test vehicle to verify noise concern is corrected. Is the concern still present?
a. a. Yes - Go to Step 6.
b. b. No - Repair complete. No further action is required.
6. Remove the brake drums per Workshop Manual (WSM), Section 206-02.
7. Clean the inner sur[aces of drums.
8. Install each brake drum on the opposite side of the vehicle.
9. Adjust the parking brake cable per WSM, Section 206-05.
10. Road test vehicle to verify concern has been corrected. Is the concern still present?
a. Yes - Machine the drums lightly to remove the groove marks. Refer to WSM, Section 206-02.
b. No - Repair complete. No further action is required.

Includes Time To Road Test and Diagnose. (Do Not Use With Any Other Labor Operations)
Technical Service Bulletins > Customer Interest: > 10-15-3 > Aug > 10 > Brakes - Rear Brake Thumping/Knocking Noise >
Page 3313
101503B 2010 Transit Connect: 1.2 Hrs.
Includes Time To Road Tests and Diagnose, Remove Both Rear Brake Drums And Swap The Left
Side Brake Drum With The Right Side Brake Drum. (Do Not Use With Any Other Labor Operations)
101503C 2010 Transit Connect: 1.8 Hrs.
Side Brake Drum With The Right Side Brake Drum, Concern Still Present. Machine Both Rear
Brake Drums. (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1126 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
Thumping/Knocking Noise
Brake Drum: All Technical Service Bulletins Brakes - Rear Brake Thumping/Knocking Noise
TSB 10-15-3
08/16/10
disappear.
SERVICE PROCEDURE
Technical Service Bulletins > All Technical Service Bulletins: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
Thumping/Knocking Noise > Page 3319
DEALER CODING
CONDITION
BASIC PART NO. CODE
1126 07
Disclaimer
Technical Service Bulletins > All Other Service Bulletins for Brake Drum: > 11-2-18 > Feb > 11 > Body - Front Door Upper
Weatherstrip Loose/Falling Off
Front Door Weatherstrip: All Technical Service Bulletins Body - Front Door Upper Weatherstrip
Loose/Falling Off
TSB 11-2-18
02/28/11
UPPER FRONT DOOR WEATHERSTRIP - LOOSE OR FALLING OFF
This article supersedes TSB 11-2-8 to update the Service Procedure and Part List.
ISSUE Some 2010 and 2011 Transit Connect vehicles built on or before 9/22/10 may exhibit an
upper front door weatherstrip loose or falling off.
SERVICE PROCEDURE
1. Remove and discard the affected upper front door weatherstrip.
2. Mark the installation position of the upper front door weatherstrip with adhesive tape for
installation. (Figure 1)
a. Apply the adhesive tape just below the upper front door weatherstrip installation position in order
to prevent over application of
BETAPRIME(TM) 5404A.
b. Using a suitable cleaning agent to remove all remaining seal residues.

c. Thoroughly clean the surface where the new upper front door weatherstrip is to be applied.
Clean the surface using a clean cloth and Isopropanol
wipe or equivalent product ensuring that the surface is dust and grease free.
3. Apply BETAPRIME(TM) 5404A to the area where the new upper front door weatherstrip is to be
applied. Allow the primer to dry for 5 minutes.
NOTE
IF THE AMBIENT TEMPERATURE FALLS BELOW 10 °C (50 °F), APPLY WARM AIR 25 °C (77
°F) CONTINUOUSLY.
4. Place the upper front door weatherstrip in the correct position. Press the upper front door
weatherstrip home for at least one minute in order to obtain
complete adhesion
a. Remove the backing film of the adhesive strip and install the upper front door weatherstrip.
b. Using a suitable tool, press the upper front door weatherstrip home for at least one minute in
order to obtain complete adhesion.
c. Remove any used tape.
5. If required, repeat steps 1 thru 4 on the opposite side.

Weatherstrip Loose/Falling Off > Page 3325
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
Connect: Replace One (1) Upper Front Door Weatherstrip Following The Service Procedure (Do
Not Use With Any Labor Operations)
110218B 2010-2011 Transit 0.5 Hr.
Connect:Replace Two (2) Upper Front Door Weatherstrips Following The Service Procedure (Do
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Weatherstrip Loose/Falling Off > Page 3331
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
110218B 2010-2011 Transit 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Brake Drum: Specifications
Maximum brake drum diameter............................................................................................................

...................................................230.2 mm (9.062 in)
Brake Drum: Service and Repair
Brake Drum
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.
NOTE: Make sure that the parking brake control is fully released.
2. NOTICE: Use of a brake drum puller or a torch is not recommended. Brake drum distortion may
result.
NOTE: If the brake drum is rusted to the axle shaft pilot diameter, tap the center of the brake drum
between the wheel studs.
Remove the brake drum.
- Adjust the rear brakes. For additional information, refer to Brake Shoe Adjustment See: Brake
Shoe/Adjustments.
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Customer Interest for Brake Shoe: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
Brake Shoe: Customer Interest Brakes - Rear Brake Thumping/Knocking Noise
TSB 10-15-3
08/16/10
disappear.
SERVICE PROCEDURE
Technical Service Bulletins > Customer Interest for Brake Shoe: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
DEALER CODING
CONDITION
BASIC PART NO. CODE
1126 07
Disclaimer
Technical Service Bulletins > Customer Interest for Brake Shoe: > 10-9-6 > May > 10 > Brakes - Rear Brake Creak On
Stationary Brake Apply
Brake Shoe: Customer Interest Brakes - Rear Brake Creak On Stationary Brake Apply
TSB 10-9-6
05/24/10
CREAK NOISE FROM REAR - WITH BRAKES APPLIED
ISSUE Some 2010 Transit Connects vehicles may exhibit a creak noise from the rear brakes, with
brakes applied and vehicle not moving.
ACTION Follow the Service Procedure to correct the condition.
SERVICE PROCEDURE
1. Remove the rear brake drums. Refer to the Workshop Manual (WSM), Section 206-02.
2. Apply Motorcraft® High Temperature Nickel Anti-Seize Lubricant or equivalent between the
upper return spring and brake shoe, at the two points
where they may touch. (Figure 1)
3. Reinstall the rear brake drums. Refer to the WSM, Section 206-02.
Parts Block
Apply Anti Seize Following Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 42
Technical Service Bulletins > Customer Interest for Brake Shoe: > 10-9-6 > May > 10 > Brakes - Rear Brake Creak On
Stationary Brake Apply > Page 3347
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
Brake Shoe: All Technical Service Bulletins Brakes - Rear Brake Thumping/Knocking Noise
TSB 10-15-3
08/16/10
disappear.
SERVICE PROCEDURE
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 10-15-3 > Aug > 10 > Brakes - Rear Brake
DEALER CODING
CONDITION
BASIC PART NO. CODE
1126 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 10-9-6 > May > 10 > Brakes - Rear Brake
Creak On Stationary Brake Apply
Brake Shoe: All Technical Service Bulletins Brakes - Rear Brake Creak On Stationary Brake Apply
TSB 10-9-6
05/24/10
CREAK NOISE FROM REAR - WITH BRAKES APPLIED
ISSUE Some 2010 Transit Connects vehicles may exhibit a creak noise from the rear brakes, with
brakes applied and vehicle not moving.
ACTION Follow the Service Procedure to correct the condition.
SERVICE PROCEDURE
1. Remove the rear brake drums. Refer to the Workshop Manual (WSM), Section 206-02.
2. Apply Motorcraft® High Temperature Nickel Anti-Seize Lubricant or equivalent between the
upper return spring and brake shoe, at the two points
where they may touch. (Figure 1)
3. Reinstall the rear brake drums. Refer to the WSM, Section 206-02.
Parts Block
Apply Anti Seize Following Service Procedure (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
2001 42
Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 10-9-6 > May > 10 > Brakes - Rear Brake
Creak On Stationary Brake Apply > Page 3358
Disclaimer
Brake Shoe: Specifications
Minimum brake shoe thickness............................................................................................................

........................................................1.0 mm (0.039 in)
Brake Shoe: Adjustments
Brake Shoe Adjustment
1. Remove the brake drum. For additional information, refer to Brake Drum See: Brake
Drum/Service and Repair.
2. Using the Brake Adjustment Gauge, measure the inside diameter of the brake drum.
3. Position the Brake Adjustment Gauge on the brake shoes and linings and adjust accordingly.
4. Install the brake drum. For additional information, refer to Brake Drum See: Brake Drum/Service
and Repair.
Brake Shoe: Service and Repair
Brake Shoes
WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
1. Remove the parking brake control boot.
- Release the boot clip.
- Lift the boot upward and over the parking brake control handle.
2. NOTE: Make sure the rear brakes are cool to the touch.
Move the parking brake control to the fully released position.
3. Relieve the tension on the parking brake cable in the following sequence.
1. Remove and discard the retaining clip.
2. Loosen the adjustment nut.
5. Remove the brake shoe retaining clips and pins.
6. Remove the upper return spring.
7. Remove the self-adjuster and spring assembly.
8. Remove the lower return spring.
9. Remove the leading brake shoe, the trailing brake shoe and parking brake actuator lever
assembly.
- Using specified brake parts cleaner, clean and dry the brake shoe contact points on the backing
plate.
- Apply a thin coat of the specified silicone grease to the brake shoe contact points on the backing
plate.
- Adjust the parking brake cable. For additional information, refer to Parking Brake System.
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Service and Repair
Wheel Cylinder: Service and Repair
Wheel Cylinder
injury.
water.
2. Remove the brake flexible hose. For additional information, refer to Brake Flexible Hose See:
Hydraulic System/Brake Hose/Line/Service and
Repair/Brake Flexible Hose.
3. Remove the brake shoe upper return spring.
4. Remove the 2 wheel cylinder bolts and the wheel cylinder.
- Bleed the wheel cylinder. For additional information, refer to Component Bleeding in Brakes and
Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Component Bleeding
Component Bleeding
Master Cylinder
injury.
water.
> Service and Repair > Component Bleeding > Page 3370
damaged.
fluid.
bubbles.

System Bleeding.
Brake Caliper
injury.
water.
screw. -
Wheel Cylinder
injury.
water.
screw. -

Pressure Bleeding
injury.
water.
bleeding operation.
Specifications.
Manual Bleeding
injury.
water.
bleeder screw. -
bleeder screw. -

Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Brake Caliper
Brake Caliper: Service and Repair Brake Caliper
Brake Caliper
injury.
water.
4. Remove the 2 guide pin bolt covers, the 2 brake caliper guide pin bolts and remove the brake
caliper.
caliper.
Traction Control.
Information > Service and Repair > Brake Caliper > Page 3380
Brake Caliper: Service and Repair Disc Brake System - Exploded View
Information > Service and Repair > Brake Caliper > Page 3381
Brake Caliper: Service and Repair Brake Caliper Anchor Plate
Brake Caliper Anchor Plate
1. Remove the brake pads. For additional information, refer to Brake Pads See: Disc Brake
System/Brake Pad/Service and Repair/Brake Pads.
2. Remove the 2 bolts and the brake caliper anchor plate.

Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications
Brake Fluid: Specifications
BRAKE FLUID
Ford Part Name - Motorcraft High Performance DOT 4 Motor Vehicle Brake Fluid
Ford Part Number - YS4Z-19542-AA
Ford Specification - ESD-M6C57-A or WSS-M6C57-A2

Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Flexible Hose
Brake Hose/Line: Service and Repair Brake Flexible Hose
Brake Flexible Hose
injury.
water.
2. Disconnect the brake tube fitting from the brake flexible hose.
3. Remove the brake flexible hose retaining clip.
4. Disconnect the brake flexible hose fitting from the wheel cylinder.
Traction Control.
Information > Service and Repair > Brake Flexible Hose > Page 3394
Brake Hose/Line: Service and Repair Front Disc Brake
Brake Flexible Hose
Brake Flexible Hose
injury.
Information > Service and Repair > Brake Flexible Hose > Page 3395
water.
- To install, tighten bolt to 14 Nm (124 lb-in).
3. Disconnect the brake tube fitting from the brake flexible hose.
4. Remove the brake flexible hose retaining clip and the brake flexible hose.
caliper.
Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Service and Repair
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Hydraulic Control Unit (HCU)

Brakes > Component Information > Service and Repair > Page 3399

injury.
water.
1. NOTE: This step is only necessary if a new ABS module is being installed on a vehicle equipped
with AdvanceTrac(R).
Connect the scan tool and upload the module configuration from the ABS module.
2. Remove the Air Cleaner (ACL). For additional information, refer to Fuel Delivery and Air
Induction.
3. Remove the brake fluid reservoir cap and using a suitable clean suction device, remove the
brake fluid from the brake fluid remote reservoir.
4. Remove the transaxle support insulator. For additional information, refer to Automatic
Transmission/Transaxle &/or Transmission Control
Systems.
5. Disconnect the PCM electrical connectors.
6. Detach the wiring harness retaining clips from the PCM bracket.
7. Remove the 3 bolts and the ACL bracket with the PCM bracket and PCM attached.
8. Remove the ground cable bolt and position the cable aside.

11. Disconnect the ABS module electrical connector by rotating the connector.
Remove the master cylinder-to-Hydraulic Control Unit (HCU) brake tubes.
Disconnect the remaining brake tubes and position aside.
- To install, tighten the LF and RR brake tube fittings to 23 Nm (17 lb-ft).
- To install, tighten the RF and LR brake tube fittings to 20 Nm (177 lb-in).
14. Remove the LF brake tube from the retaining clip on the LH inner frame rail.
15. Remove the 3 HCU bracket-to-frame nuts and remove the HCU and bracket assembly from the
vehicle.

16. Remove the 2 HCU-to-bracket bolts and separate the HCU from the support bracket.
1. If a new ABS module was installed on a vehicle equipped with AdvanceTrac(R) with Roll Stability
Control (RSC(R)), download the module
configuration information from the scan tool. For additional information, refer to Information Bus.
2. If a new ABS module or HCU was installed on a vehicle equipped with AdvanceTrac(R) with
RSC(R), carry out the IVD Initialization
sequence for all 4 stability control sensors (roll rate, yaw rate, lateral acceleration, longitudinal
acceleration), the steering angle sensor and the brake fluid pressure sensor. Follow the scan tool
directions.
3. Bleed the brake system. For additional information, refer to Brakes and Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Component Tests
Brake Master Cylinder: Testing and Inspection Component Tests
Brake Booster
Component Tests
Brake Booster
1. Disconnect the check valve from the brake booster and connect a suitable vacuum/pressure
tester to the booster side of the check valve.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
- Allow the engine to reach normal operating temperature.
3. NOTE: Subtract approximately 4.0193 kPa (1 in-Hg) from the specified reading for every 304.8
m (1,000 ft) of elevation above sea level.
Verify that vacuum is available at the check valve with engine running at normal idle speed.
- The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
- If specified vacuum is available, stop the engine, connect the check valve and continue with Step
5.
- If specified vacuum is not available, continue with Step 4.
4. Disconnect the check valve from the vacuum hose and verify that the specified vacuum is
available at the hose with the engine at idle speed and
the transmission in NEUTRAL. -
If specified vacuum is available, stop the engine, install a new check valve and continue with Step
5.
- If specified vacuum is not available, stop the engine, connect the vacuum hose to the check valve
and refer to Engine to diagnose the no/low vacuum condition.
5. Apply the brake pedal several times to exhaust all vacuum from the system.
6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the
brake pedal moves downward after the engine starts.
- If the brake pedal moves, the brake booster is operating correctly.
- If the brake pedal does not move, install a new brake booster. Refer to Power Brake Assist.
7. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand
for 10 minutes, then apply the brake pedal. The
brake pedal feel should be the same as that noted with the engine operating. -
If the brake pedal feels hard (no power assist), install a new brake booster check valve and retest.
- If condition still exists, install a new brake booster. Refer to Power Brake Assist.
- If the brake pedal feels the same as noted with the engine operating, the check valve is
functioning properly.
Brake Master Cylinder - Bypass Condition

Component Tests
Brake Master Cylinder - Bypass Condition
1. Inspect the master cylinder. Refer to Brake System Inspection See: Testing and
Inspection/Component Tests and General Diagnostics/Brake
System Inspection.
2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.
4. NOTE: Make sure that the outlet port plugs do not show signs of leakage.
Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy
force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak
and a new brake master cylinder must be installed.
Information > Testing and Inspection > Component Tests > Page 3406
- If brake pedal height is maintained, reinstall brake tubes and tighten to specifications. Refer to
Specifications. After installation, bleed the brake system. Refer to Brake System Bleeding See:
Brake Bleeding/Service and Repair/Brake System Bleeding.
Brake Master Cylinder - Compensator Port
Component Tests
Brake Master Cylinder - Compensator Port
1. Inspect the master cylinder. Refer to Brake System Inspection See: Testing and
Inspection/Component Tests and General Diagnostics/Brake
System Inspection.
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Vehicle Jacking and Lifting.
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 that the brake pedal is
not partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the
brake booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag.
- If the brake drag is no longer present, install a new brake booster. Refer to Power Brake Assist.
- If the brake drag is still present, install a new master cylinder. Refer to Hydraulic System, Brakes
&/or Brake Pedal Assy.
Brake Master Cylinder: Testing and Inspection Brake System Inspection
Brake Pads
Brake System Inspection
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect and measure the thickness of the brake pad friction material. For additional information,
refer to Specifications.
- Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads. For additional information,
refer to Disc Brake System for front brake pads.
- If the thickness of the friction material is less than the specified thickness, install new brake pads.
For additional information, refer to Disc Brake System for front disc brakes.
- If the friction material shows taper wear that is not within specifications, install new brake pads
and verify the caliper guide pins are functioning correctly. For additional information, refer to Brake
Caliper Guide Pins inspection. See: Testing and Inspection/Component Tests and General
Diagnostics/Brake System Inspection/Brake Caliper Guide Pins
Brake Shoes
Brake Shoes
1. Inspect and measure the thickness of the brake shoe friction material. For additional information,
- Minor surface cracks do not require shoe replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake shoes.
- If the thickness of the friction material is less than the specified thickness, install new brake
shoes.
- Verify that the mounting hardware is installed correctly and operating correctly. Install new
hardware as necessary.
- Verify that the backing plate contact points are free of corrosion that may cause binding. Clean or
install new as necessary.
- Verify correct brake shoe adjustment.
- For additional information, refer to Drum Brake System.
Brake Discs

Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts.
This causes brake disc on-vehicle lateral runout and brake roughness.
NOTE: It is generally not required to install new brake discs to address noise issues.
1. Inspect the brake disc and measure the brake disc thickness. Record the measurement, refer to
Specifications.
- If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Disc Brake System for front brakes.
- If the measurement is below the minimum thickness specification, install a new brake disc. For
additional information, refer to Disc Brake System for front brakes.
- If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to machine,
discs must be above the minimum thickness specification. For additional information, refer to
Specifications and Brake Disc Machining See: Disc Brake System/Brake Rotor/Disc/Service and
Repair/Procedures.
Brake Drums
Brake Drums
NOTE: It is generally not required to install new brake drums to address noise issues.
1. Inspect the brake drums and measure the brake drum diameter. Record the measurements,
- If the brake drum is cracked or otherwise damaged, install a new brake drum.
- If the diameter measurement is more than the maximum specification, install a new brake drum.
- Heavily scored brake drums, similar to that caused by shoes worn down to the backing plate,
should be machined. In order to machine, drums must be below the maximum diameter
specification.
- For additional information, refer to Drum Brake System.
Wheel Cylinders
Wheel Cylinders
1. Inspect the wheel cylinders for leaks, damage to seals, and piston corrosion or binding.
- If the wheel cylinder is leaking or otherwise damaged, install a new wheel cylinder. For additional
information, refer to Drum Brake System.
Brake Calipers
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals, and piston corrosion or binding.
- If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For additional
information, refer to Disc Brake System for front brake calipers.
Brake Caliper Guide Pins
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show
taper wear or the guide pins are difficult to move,
carry out the following steps. -
Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear,
damage and corrosion. If bore is worn or damaged, replace the damaged component.
- Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material
from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake
parts cleaner and compressed air.
- Assemble the caliper guide pins using new caliper seals, boots and guide pins. Use an ample
amount of the specified grease to lubricate the bores and guide pins.
- Inspect the brake pads. For additional information, refer to Brake System Inspection. See: Testing
and Inspection/Component Tests and General Diagnostics/Brake System Inspection
Brake Flexible Hoses and Tubes
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result
in brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube
fittings must be correctly double flared to provide strong, leakproof connections. When bending
tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
- If a section of the brake tube is damaged, the entire section must be installed with a new tube of
the same type, size, shape and length.
- When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to Brake
System Bleeding See: Brake Bleeding/Service and Repair/Brake System Bleeding.
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any
other signs of damage.
- Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage.
For additional information, refer to Disc Brake System for the front brake flexible hose or Drum
Brake System for the rear brake flexible hose.
Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master
cylinder reservoir will fall during brake application and rise during release. The net fluid level (such
as after brake application and release) will remain unchanged. Fluid level will decrease with pad
wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting
flange. This results from the normal lubricating action of the master cylinder bore and seal.
1. Inspect the brake master cylinder for fluid leaks.
- Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. For
additional information, refer to Hydraulic System, Brakes &/or Brake Pedal Assy.
- To check for correct brake master cylinder operation, refer to Component Tests See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests.
Brake Booster
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for
leaks and kinks.
- Install a new brake booster if signs of excessive corrosion or damage is found. For additional
information, refer to Power Brake Assist.
- Repair or replace vacuum hoses as necessary.
- To check for correct brake booster operation, refer to Component Tests See: Testing and
Inspection/Component Tests and General Diagnostics/Component Tests.
Information > Service and Repair > Brake Master Cylinder
Brake Master Cylinder: Service and Repair Brake Master Cylinder

injury.
water.
1. With the engine OFF, press the brake pedal several times to deplete the brake booster vacuum.
- To install, tighten 10 Nm (89 lb-in).

Information > Service and Repair > Brake Master Cylinder > Page 3413
6. NOTE: Cap the hose connections to prevent fluid loss.
Disconnect the brake fluid reservoir-to-master cylinder tube.
7. NOTE: Cap the brake tube connections to prevent fluid loss.
damaged. -
To install, tighten to 23 Nm (17 lb-ft).
8. NOTE: Make sure that the master cylinder-to-booster seal is removed with the master cylinder.
Remove and discard the 2 brake master cylinder nuts and remove the brake master cylinder.
- Discard the master cylinder-to-booster seal.
- To install, tighten the new nuts to 25 Nm (18 lb-ft).
9. NOTE: Before installing the master cylinder, make sure that the new master cylinder-to-booster
seal is in place and that the mating faces are
clean.

- Bleed the master cylinder. For additional information, refer to Brakes and Traction Control.
Brake Master Cylinder: Service and Repair Brake Fluid Reservoir

Brake Fluid Reservoir
injury.
water.
NOTE: The brake fluid remote reservoir and brake fluid reservoir can be serviced separately.
1. Disconnect the electrical connector from the brake fluid remote reservoir filler cap.

6. NOTE: Cap the hose connections to prevent fluid loss.
Disconnect the brake fluid remote reservoir-to-master cylinder tube.
7. Remove the 2 brake fluid remote reservoir bolts.
8. Remove the brake fluid remote reservoir.
9. Remove the brake fluid reservoir pin bolt and the brake fluid reservoir.
10. Remove and discard the 2 brake fluid reservoir seals.
11. NOTE: Install new brake fluid reservoir seals. Lubricate the seals with clean, specified brake
fluid.
- Bleed the master cylinder. For additional information, refer to Brakes and Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Wheel Cylinder: Service and Repair
Wheel Cylinder
injury.
water.
1. Remove the brake drum. For additional information, refer to Brake Drum See: Drum Brake
System/Brake Drum/Service and Repair.
2. Remove the brake flexible hose. For additional information, refer to Brake Flexible Hose See:
Brake Hose/Line/Service and Repair/Brake
Flexible Hose.
3. Remove the brake shoe upper return spring.
4. Remove the 2 wheel cylinder bolts and the wheel cylinder.
Traction Control.
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Parking Brake Cable: Adjustments
Parking Brake Cable Adjustment
2. Release the parking brake.
3. Loosen parking brake cable adjustment nut until there is no tension in the cable.
4. Apply the service brakes several times to verify the rear brake shoes are correctly adjusted.
5. Raise the parking brake control 7 clicks.
6. NOTE: If rear cables are installed new, tighten parking brake adjustment nut to 5 Nm (44 lb-in)
and loosen then tighten to 3 Nm (27 lb-in).
Tighten the parking brake cable adjustment nut to 3 Nm (27 lb-in).
7. Apply and release the parking brake control several times with sufficient force to settle the
parking brake system.
8. Release the parking brake control to its lowest position.
9. Rotate the rear wheels to make sure the brake shoes do not drag.
10. Install the parking brake control boot.

Information > Service and Repair > Parking Brake Cable
Parking Brake Cable: Service and Repair Parking Brake Cable
Parking Brake Cable
Front cable
1. Remove the parking brake control. For additional information, refer to Parking Brake Control
See: Parking Brake Control/Service and
Repair/Parking Brake Control.
Rear cables
4. Loosen the parking brake cable adjustment nut to the end of the threads.
All cables
6. Remove the 4 nuts, the screw and position the exhaust center heat shield aside.
7. Separate the front parking brake cable from the equalizer.
Front cable
8. Position the cable grommet up through the floor.
Rear cables
9. Remove the 5 nuts, the screw and the front fuel tank heat shield.
10. Remove the 5 nuts, the screw and position the rear fuel tank heat shield aside.
11. Remove the parking brake cables from the bracket.
12. Remove the 4 parking brake cable bracket bolts from the floor panel.
13. Remove the 2 parking brake cable wire form bracket bolts.
14. Remove the brake shoes. For additional information, refer to Drum Brake System.
15. Compress the clips and pull the parking brake cables through the brake backing plates.
16. NOTE: The RH cable can be identified by a sleeve near the equalizer.
- Adjust the parking brake. For additional information, refer to Parking Brake Cable Adjustment
See: Adjustments.
Information > Service and Repair > Parking Brake Cable > Page 3426
Parking Brake Cable: Service and Repair Parking Brake - Exploded View
Parking Brake - Exploded View
Parking Brake (View 1 of 3)

Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Service and Repair > Parking Brake Control
Parking Brake Control: Service and Repair Parking Brake Control
Parking Brake Control
4. Disconnect the parking brake cable from the parking brake control.
- Remove the adjustment nut and washer.
- Discard the adjustment nut.
5. Remove the 2 parking brake control bolts and the parking brake control.
- Install a new adjustment nut.
- Adjust the parking brake. For additional information, refer to Parking Brake Cable Adjustment
See: Parking Brake Cable/Adjustments.
Information > Service and Repair > Parking Brake Control > Page 3433
Parking Brake Control: Service and Repair Parking Brake - Exploded View

Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Parking Brake Shoe: Diagrams

Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Vacuum Brake Booster: Specifications
Vacuum Brake Booster: Description and Operation
Brake Booster
The brake booster consists of:
- Brake booster assembly
- Brake booster vacuum hose
- Brake booster vacuum check valve
The brake booster is a single-diaphragm type which utilizes engine vacuum to reduce brake pedal
effort and travel. The brake booster is divided into separate vacuum and atmospheric chambers by
the diaphragms. Engine vacuum is supplied to the brake booster through the brake booster hose
and a one-way check valve. The check valve retains the engine vacuum in the brake booster and
allows for several power-assisted brake applications with the engine off.
When the brake pedal is applied, vacuum replaces the atmospheric pressure in the brake booster,
reducing the effort required at the brake pedal to slow the vehicle. When the brake pedal is
released, vacuum returns to the brake booster through the brake booster vacuum hose and check
valve.
Vacuum Brake Booster: Service and Repair
Brake Booster
1. Remove the Hydraulic Control Unit (HCU). For additional information, refer to Antilock Brakes /
Traction Control Systems.
2. Remove the brake master cylinder. For additional information, refer to Hydraulic System, Brakes
&/or Brake Pedal Assy.
3. Disconnect the vacuum hose/check valve assembly from the brake booster.
4. Detach the heater hose bracket pin-type retainer from the cowl.
5. Remove the lower steering column cover. For additional information, refer to the Instrument
Panel - Exploded View in Instrument Cluster / Carrier
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.
6. Remove the stoplamp switch.
7. Disengage the locking tab and remove the brake booster rod pin.
8. Remove the brake booster nuts.
9. Remove the brake booster.
10. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This 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 this switch with the brake pedal in any other position will result in incorrect adjustment
and may damage the switch.
- Make sure the brake booster gasket is correctly positioned on the brake booster before
installation.
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest for Electronic Brake
Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 3462
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely
Prematurely
TSB 11-2-11
02/07/11
Time Standards.
SERVICE PROCEDURE
3.
Step 4.
Proceed to Step 4.
206-03.
NOTE
ONLY.
NOTE
NOTE
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > 11-2-11 > Feb > 11 > Brakes - Front Brake Pads Wear Prematurely > Page 3468
110211A 2010-2011 Transit 1.1 Hrs.
110211B 2010-2011 Transit 0.8 Hr.
110211C 2010-2011 Transit 1.3 Hrs.
110211D 2010-2011 Transit 1.0 Hr
110211E 2010-2011 Transit 0.3 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
Disclaimer
Brake Control Module > Component Information > Technical Service Bulletins > Page 3469

Unit (HCU) See: Antilock Brakes / Traction
Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair.

Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > ABS
Sensor Block > Component Information > Locations > Page 3478

Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
cluster.

Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Fluid Level Sensor/Switch > Component Information > Locations > Page 3485
Fluid Level Sensor/Switch > Component Information > Locations > Page 3486
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Brake Warning Switch > Component Information > Locations > Page 3490
Brake Warning Switch > Component Information > Locations > Page 3491
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair
Removal
Installation

procedure.

Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Service and Repair > Page 3495
directions.
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front
Speed Sensor > Component Information > Locations > Wheel Speed Sensor, Left Front > Page 3500
Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front

Speed Sensor > Component Information > Diagrams > Wheel Speed Sensor, Left Front > Page 3505

Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front

clips.

Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Front > Page 3512
clips.
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Removal and Replacement

Assembly

Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
Battery Cable: Service and Repair
Battery Cables
> Page 3541
Both cables
1. Remove the battery tray. For additional information, refer to Battery Tray See: Service and
Repair/Battery Tray.
Air Induction.
Battery ground cable
3. Remove the nut and position the battery ground cable body terminal aside.

4. Remove the bolt and position the battery ground cable engine terminal aside.
5. Remove the battery ground cable.
Positive battery cable
6. Remove the nut and position the Battery Junction Box (BJB) terminal aside.
7. Disconnect the positive battery cable from the engine control harness connector.
8. Remove the starter solenoid terminal nut.
9. Remove the starter solenoid wire terminal nut.
10. Disconnect the positive battery cable from the starter solenoid.
11. Remove the 2 positive battery cable clips.
12. Remove the 4 alternator battery cable locators.
13. Position aside the generator B+ boot, remove the nut and position the generator B+ terminal
aside.
> Page 3542
14. Remove the positive battery cable and alternator cable.

Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Specifications > Electrical Specifications > Page 3548
Alternator: Mechanical Specifications
Alternator: Diagrams
Alternator: Description and Operation
Charging System
The charging system is a negative ground system consisting of:
- a generator with an internal voltage regulator.
- a charging system warning indicator.
- a battery.
- circuitry and cables.
- a PCM.
- a radial arm adapter (serviceable separately from the generator)
The generator is driven by the accessory drive belt. When the engine is started, the generator
begins to generate AC which is internally converted to DC. The DC is controlled by the voltage
regulator (located on the rear of the generator) and supplied to the battery. The PCM controls the
voltage regulation set point, working with the generator internal voltage regulator over 2 control and
communication circuits.
Alternator: Service and Repair
Generator
Removal
2. Disconnect the battery. For additional information, refer to Battery.
3. Disconnect the generator electrical connector.
4. Remove the RH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
5. Remove the 3 bolts and the center support bracket.
6. Remove the 2 screws and the accessory drive splash shield.

7. Rotate the Front End Accessory Drive (FEAD) belt tensioner clockwise and remove the belt from
the generator drive pulley. Position the FEAD
belt aside.
8. Release the 2 retainers and remove the lower generator air duct.
9. Position the protective cover aside, remove the nut and position the generator B+ terminal aside.
10. Remove the 2 generator mounting nuts.
11. Remove the 2 generator studs.
12. Remove the generator mounting bolt and the generator.
13. If necessary, remove the bolt and the generator upper air duct.
Installation
1. If removed, install the generator upper air duct and the bolt.
2. Install the generator and generator mounting bolt. Hand-tighten the bolt. Do not tighten the bolt
at this time.
3. Install the 2 generator studs.
4. Install the 2 generator mounting nuts.
5. Tighten the generator bolt.
6. Position the generator B+ terminal on the generator and install the nut.
- Tighten the nut to 12 Nm (106 lb-in) and position the protective cover on the nut.
7. Install the lower generator air duct.
8. Rotate the FEAD belt tensioner clockwise and install the FEAD belt.
9. Position the accessory drive splash shield and install the 2 screws.
- Tighten the screws to 5 Nm (44 lb-in).
10. Install the center support bracket and the 3 bolts.
- Tighten the bolts to 30 Nm (22 lb-ft).
11. Install the RH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.
12. Connect the generator electrical connector.
13. Connect the battery. For additional information, refer to Battery.

Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Removal and Replacement

Component Information > Service and Repair > Removal and Replacement > Page 3559
Assembly

Ford Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Testing and
Inspection > Key Programming Switch State Control
Key: Testing and Inspection Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED,
the Key Programming Using Two Programmed Keys procedure does not function. This switch is
set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two
Programmed Keys procedure.
1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter
(IKT)) PATS key (if equipped) into the ignition
lock cylinder and turn the key from the OFF position to the ON position.
2. From the scan tool, enter TOOLBOX. Select BODY - SECURITY - PATS Functions and follow
the IDS on-screen instructions to ENTER
SECURITY ACCESS. For additional information, refer to Anti-Theft Security Access See:
Inspection/Component Tests and General Diagnostics.
3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC
SPAREKEY PID.
From the scan tool menu select: "Customer Spare Key Programming Enable" and follow the IDS
on-screen instructions in order to complete the procedure. -
"Customer Spare Key Programming Enable" - spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - spare key programming procedure is not
accessible.
Inspection > Key Programming Switch State Control > Page 3566
Key: Testing and Inspection Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the
vehicle does not start until 2 keys are programmed to the vehicle. This procedure does not erase
the Integrated Keyhead Transmitter (IKT) identification codes (Transmitter Identification Codes
(TICs)) from the Generic Electronic Module (GEM).
NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before
the vehicle starts.
NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the
correct mechanical cut must be available to carry out this procedure. One or both of them may be
the customer's original keys. One or both of them may be an IKT key or a standard PATS key. If
the vehicle is not equipped with IKT keys, 2 standard PATS keys are sufficient to complete this
procedure.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the IC SPAREKEY PID must be enabled.
NOTE: This procedure is not necessary if only the PATS transceiver was replaced. Replacement of
the transceiver does not erase the PATS key codes in the IC.
1. Turn the PATS key from the OFF position to the ON position.
the Integrated Diagnostic System (IDS)
on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to

Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase". Follow all IDS screen instructions
until the key erase procedure completes. The scan
tool also instructs to program 2 keys to complete the process.

4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be
removed from the ignition lock cylinder at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for a minimum of 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
7. Insert the second PATS key into the ignition lock cylinder and turn the key to the ON position for
a minimum of 3 seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
10. NOTE: Erasing the keys with the scan tool does not erase the RKE transmitter portion of an
IKT PATS key (if equipped) on this vehicle.
Programming the PATS keys using the scan tool or using the Key Programming Using Two
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys
procedure does not program the RKE transmitter portion of the IKT PATS key on this vehicle only.
To program the RKE transmitter portion of an IKT PATS key (if equipped), refer to Doors, Hood and
Trunk &/or Locks.
Key: Testing and Inspection Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be
Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft
System (PATS) keys are not available, refer to Key Programming Using Diagnostic Equipment
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, in order to enable the customer spare key
programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the
anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft in the Diagnosis and Testing to review the DTCs and carry out
the appropriate pinpoint tests. See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle starts.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the Owner's Literature for instructions on
programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure ends.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be
PATS-encoded keys (contain a transponder). The key does not have to be an IKT key.
NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can
be IKTs (if equipped). If an attempt to program more than 4 IKTs occurs, the additional IKTs do not
have any Remote Keyless Entry (RKE) function capability. The PATS portion of the additional key
functions, but the RKE transmitter function cannot be programmed.
1. Insert a programmed ignition PATS key (can be an IKT or a standard PATS key) into the ignition
lock cylinder and turn the key from the OFF
position to the ON position.
2. Leave the key in the ON position for 3 seconds, but not longer than 10 seconds.
3. Turn the key to the OFF position and remove the first key.
4. Within 10 seconds of turning the key to the OFF position, insert a second programmed PATS
ignition key (can be an IKT or a standard PATS key)
into the ignition lock cylinder and turn the key from the OFF position to the ON position.
6. Turn the key to the OFF position and remove the second key.
7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed PATS
ignition key (new PATS or IKT key) into the ignition
lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON
position for a minimum of 3 seconds.
8. NOTE: The new key now starts the vehicle.
Start the vehicle with the new key.
- If it is an IKT key, follow step 10 below to program the RKE transmitter portion of the IKT key.
9. If additional programmed keys are desired, repeat Steps 1-7.
10. To program the RKE transmitter portion of an IKT PATS key (if equipped), refer to Doors, Hood
and Trunk &/or Locks.
Key: Testing and Inspection Spare Key Programming - Using Diagnostic Equipment
Spare Key Programming - Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs to have an additional key programmed into
the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This
procedure is also useful when attempting to determine if an ignition key is damaged, as a new key
can be installed without erasing keys or without having 2 programmed keys available.
NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock
cylinder.
NOTE: If 8 keys are already programmed, this procedure does not allow any more Passive
Anti-Theft System (PATS) keys to be programmed. The number of keys that are programmed into
the PATS can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE.
1. Turn the unprogrammed PATS key from the OFF position to the ON position.
3. NOTE: Make sure the selection made is "Program additional ignition key". If the "Ignition Key
Code Erase" selection is made, all of the keys are
erased from the system.
From the scan tool menu select: "Program additional ignition key".
4. Turn the key to the OFF position and disconnect the scan tool.
5. Start the vehicle with the new PATS key. The vehicle starts with the new PATS key and also with
the original PATS keys.
Key: Testing and Inspection Passive Anti-Theft System (PATS) Parameter Reset
Passive Anti-Theft System (PATS) Parameter Reset
NOTE: A minimum of 2 Passive Anti-Theft System (PATS) keys must be programmed into the
Instrument Cluster (IC) to complete this procedure and allow the vehicle to start.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For
additional information, refer to Anti-Theft Security
Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics .
3. From the scan tool, select: Parameter Reset and follow the on-screen instructions.
4. NOTE: If the IC or the IC and the PCM were replaced, updated or reconfigured, follow Steps 4-9.
All vehicle keys are erased during the
parameter reset procedure. Verify at least 2 vehicle keys are available prior to carrying out the
PATS parameter reset. If only the PCM was replaced, go to Step 9.
From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions.
6. Turn the key to the ON position for 6 seconds.
7. Turn the key to the OFF position and remove the key.
6 seconds.
9. Both keys now start the vehicle.
10. If more keys are required to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional

Programming Using Two Programmed Keys.
11. Program the Remote Keyless Entry (RKE) transmitter portion of the Integrated Keyhead
Transmitter (IKT) PATS keys. For additional
information, refer to Doors, Hood and Trunk &/or Locks.

Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
Specifications > Electrical Specifications > Page 3580
Starter Motor: Mechanical Specifications
Starter Motor: Locations
Starter Motor: Diagrams

Starter Motor: Service and Repair
Starter Motor
WARNING: Always disconnect the battery ground cable at the battery before disconnecting the
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool
can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
3. Remove the starter solenoid wire nut.
4. Remove the starter solenoid battery cable nut and the starter motor solenoid wire harness
terminal cover.
5. Detach the Engine Oil Pressure (EOP) switch wire harness retainer from the starter stud bolt.
6. Remove the power steering tube bracket nut and position the power steering tube and bracket
aside.
7. Remove the upper bolt, the lower stud bolt and the starter motor.
- To install, first install the upper bolt and lower stud bolt finger-tight.
- Tighten the upper bolt to 35 Nm (26 lb-ft).
- Tighten the lower stud bolt to 35 Nm (26 lb-ft).

Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Power Point, Front
Auxiliary Power Outlet: Diagrams Power Point, Front

Information > Diagrams > Power Point, Front > Page 3599
Auxiliary Power Outlet: Diagrams Power Point, Rear
Information > Diagrams > Power Point, Front > Page 3600
Auxiliary Power Outlet: Service and Repair
Power Point
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
Installation
1. Connect the electrical connector.
2. Slide the power point socket into the retainer.

Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Electronic Noise Suppressor: Diagrams
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Battery Junction Box (BJB)
Locations > Battery Junction Box (BJB) > Page 3610

Application and ID > Battery Junction Box (BJB)
Application and ID > Battery Junction Box (BJB) > Page 3618

Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Battery Junction Box (BJB)
> Locations > Battery Junction Box (BJB) > Page 3625
> Locations > Battery Junction Box (BJB) > Page 3626
> Diagrams > Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
> Diagrams > Diagram Information and Instructions > Page 3629
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.

Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C110
Multiple Junction Connector: Diagrams C110
Component Information > Diagrams > C110 > Page 3653

Multiple Junction Connector: Diagrams
C110
C126
C139
C211
C213
C215
C219
C237
C268
C339A
C339B
C339C
C340A
C340B
C340C
C340D
C340E
C340F
C406
C421
C423
C431
C432
C438
C510
C610
C1045
C3249
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relays - Micro
Ground Distribution > Power Distribution Relay > Component Information > Testing and Inspection > Relays - Micro > Page
3695
3696
3697
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB)
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 3702
Ground Distribution > Relay Box > Component Information > Locations > Battery Junction Box (BJB) > Page 3703
Ground Distribution > Relay Box > Component Information > Locations > Page 3704
Relay Box: Diagrams

Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB)
Ground Distribution > Relay Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 3707

Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Battery Junction Box (BJB)
Relay Box: Diagrams

Application and ID > Battery Junction Box (BJB)

Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL
ON/Multiple DTC's Stored In Memory
Wiring Harness: Customer Interest Electrical - MIL ON/Multiple DTC's Stored In Memory
TSB 10-15-1
08/16/10
P07XX, P0642, P0138, P0141, P0219 AND/OR ERRATIC SHIFTING AND/OR ERRATIC
SPEEDOMETER - BUILT ON OR BEFORE 12/29/2009
ISSUE Some 2010 Transit Connect vehicles built on or before 12/29/2009 may exhibit a
malfunction indicator light (MIL) on with or without diagnostic trouble codes (DTCs) PO7XX, P0642,
P0138, P0141, P0219 and/or erratic transmission shifting and/or erratic speedometer. The
customer may report that the condition occurs only when the vehicle is in reverse. The condition
may be related to the increase in engine roll when the vehicle is in reverse.
SERVICE PROCEDURE
1. Remove the powertrain control module (PCM). Refer to Workshop Manual (WSM), Section
303-14.
2. Remove the battery tray. Refer to WSM, Section 414-04.
3. Inspect the wiring from C175T for possible chafing, especially when the vehicle is placed in
reverse. Engine roll may cause this harness to chafe
against the thermostat housing hose clamp. (Figure 1)
4. Repair any chafed wiring as necessary.

5. Reposition the wiring harness away from the thermostat housing hose clamp and tie strap
(obtained locally) to the battery hold down screw.
6. Reinstall the battery tray. Refer to WSM, Section 414-04.
7. Reinstall the PCM. Refer to WSM, Section 303-14.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And
Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a
TSB. Warranty coverage limits are determined by the identified causal part.
MT01501 Claim Diagnosis And Labor Actual
Performed As Actual Time Time
DEALER CODING
CONDITION
Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL
ON/Multiple DTC's Stored In Memory > Page 3730
BASIC PART NO. CODE
12B637 30
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-15-1 > Aug > 10 >
Electrical - MIL ON/Multiple DTC's Stored In Memory
Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/Multiple DTC's Stored In
Memory
TSB 10-15-1
08/16/10
SERVICE PROCEDURE
303-14.

DEALER CODING
CONDITION
Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-15-1 > Aug > 10 >
Electrical - MIL ON/Multiple DTC's Stored In Memory > Page 3736
BASIC PART NO. CODE
12B637 30
Disclaimer
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Power Point, Front
Auxiliary Power Outlet: Diagrams Power Point, Front

Power Point, Front > Page 3742
Auxiliary Power Outlet: Diagrams Power Point, Rear
Power Point, Front > Page 3743
Page 3744
Auxiliary Power Outlet: Service and Repair
Power Point
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
Installation
2. Slide the power point socket into the retainer.

Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams
Electronic Noise Suppressor: Diagrams
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Diagrams > Page 3748
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction
Box (BJB)
Box (BJB) > Page 3753

Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery
Junction Box (BJB)
Junction Box (BJB) > Page 3761

Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Battery
Junction Box (BJB)
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
Information and Instructions > Page 3772
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.

Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C110
Diagrams > C110 > Page 3796

Multiple Junction Connector: Diagrams
C110
C126
C139
C211
C213
C215
C219
C237
C268
C339A
C339B
C339C
C340A
C340B
C340C
C340D
C340E
C340F
C406
C421
C423
C431
C432
C438
C510
C610
C1045
C3249
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Testing
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Testing and Inspection > Relays - Micro
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Battery Junction Box (BJB)
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 3845
Box > Component Information > Locations > Battery Junction Box (BJB) > Page 3846
Box > Component Information > Locations > Page 3847
Relay Box: Diagrams

Box > Component Information > Application and ID > Battery Junction Box (BJB)
Box > Component Information > Application and ID > Battery Junction Box (BJB) > Page 3850

Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Battery
Junction Box (BJB)
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3859
Relay Box: Diagrams

Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >

Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Customer Interest for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL ON/Multiple DTC's Stored In
Memory
Wiring Harness: Customer Interest Electrical - MIL ON/Multiple DTC's Stored In Memory
TSB 10-15-1
08/16/10
SERVICE PROCEDURE
303-14.

DEALER CODING
CONDITION
Bulletins > Customer Interest for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL ON/Multiple DTC's Stored In
Memory > Page 3873
BASIC PART NO. CODE
12B637 30
Disclaimer
Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL ON/Multiple DTC's
Stored In Memory
Memory
TSB 10-15-1
08/16/10
SERVICE PROCEDURE
303-14.

DEALER CODING
CONDITION
Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-15-1 > Aug > 10 > Electrical - MIL ON/Multiple DTC's
Stored In Memory > Page 3879
BASIC PART NO. CODE
12B637 30
Disclaimer
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Alignment
Specifications
Alignment: Specifications Alignment Specifications
Alignment Specifications (at curb weight)

Alignment: Specifications General Specifications
Alignment: Specifications Torque Specifications
a Refer to the procedure.

Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 3887
Alignment: Description and Operation
Wheel Alignment Angles
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut
and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the
best directional stability characteristics when loaded and driven. The caster setting is not related to
tire wear. The caster setting is not adjustable.
A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a
separate procedure on this vehicle. Front caster should fall within specification when the front
camber is adjusted.
Toe
Positive Toe (Toe In)
Negative Toe (Toe Out)

The vehicle toe setting affects tire wear and directional stability.
Incorrect Thrust Angle (Dogtracking)
Incorrect thrust angle (also known as dogtracking) is the condition in which the rear axle is not
square to the chassis. Heavily crowned roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering
wheel resulting from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and experienced by the driver as small rotational oscillations of the steering wheel.
For wheel and tire diagnosis, refer to Wheels and Tires.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering are used to describe the poor return of the steering wheel to
center after a turn or steering correction.
Drift/Pull
Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
- A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead
path and requires constant steering input in the opposite direction to counteract the effect.
- Drift/pull may be induced by conditions external to the vehicle (wind or road crown).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20 degrees of steering wheel turn). Effort may be said to be "flat on-center."
- Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the
gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the
effort from the self-aligning forces at the road wheel or tire patch.
- In the diagnosis of a driveability problem, it is important to understand the difference between

wander and poor groove feel.
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment - Front
Alignment: Service and Repair Camber and Caster Adjustment - Front
Camber and Caster Adjustment - Front
Camber Adjustment
2. NOTE: By loosening the strut rod nut and either pushing the strut inboard or pulling it outboard
the camber can be adjusted by approximately
0.25 degree.
Loosen the strut rod nut.

- To make a negative camber adjustment, loosen the strut rod nut and push the strut inboard.
- To make a positive camber adjustment, loosen the strut rod nut and pull the strut outboard.
- Tighten the nut to 59 Nm (44 lb-ft).
To make a positive camber adjustment, loosen the wheel knuckle-to-strut bolt with the vehicle
supported by the subframe. This will allow the strut to sit on the wheel knuckle-to-strut bolt.
To make a negative camber adjustment, loosen the wheel knuckle-to-strut bolt with the weight of
the vehicle on the wheel and tire. This will allow the struts weight to fully lift up on the wheel
knuckle-to-strut bolt.

Caster Adjustment - Front > Page 3892
module.
directions.
Cross Camber Adjustment
3. NOTE: Shifting the subframe towards the passenger side will increase the driver side camber
and decrease the passengers side camber. Shifting
the subframe towards the driver side will increase the passenger side camber and decrease the
drivers side camber.
Shift the subframe to change the cross camber as required.
module.
directions.
Cross Caster Adjustment
1. Using alignment equipment and the manufacturer's instructions, measure the caster settings.
3. NOTE: Shifting the subframe forward will increase the caster. Shifting the subframe rearward will
decrease the caster.
Shift the subframe to change the cross caster as needed.
module.
directions.
Alignment: Service and Repair Toe Adjustment - Front
Toe Adjustment - Front
1. Using a suitable steering wheel holding device, lock the steering wheel in the straight ahead
position.
2. Using alignment equipment and the manufacturer's instructions, measure the toe.
3. Loosen the tie-rod jam nuts.
4. Remove the steering gear boot outer clamps.
5. Rotate the tie rods as necessary to adjust the toe setting.
6. Tighten the tie-rod jam nuts to 80 Nm (59 lb-ft).
7. Install the steering gear boot outer clamps.
8. Recheck the toe settings, adjust as necessary.
module.
directions.
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations
Modules - Wheels and Tires > Tire Pressure Module > Component Information > Locations > Page 3900

Removal
damage may result.
to Information Bus.
Installation

System (TPMS) Sensor Training See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Monitors, Trips, Drive Cycles and Readiness Codes.
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 3911

Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

Steering Pressure (PSP) Switch > Page 3914
Sensor
parking maneuvers.
Typical PSP Sensor

Switches - Steering > Power Steering Pressure Switch > Component Information > Description and Operation > Page 3915

Switches - Steering > Steering Angle Sensor > Component Information > Locations
Switches - Steering > Steering Angle Sensor > Component Information > Locations > Page 3919

Switches - Suspension > Steering Angle Sensor > Component Information > Locations
Switches - Suspension > Steering Angle Sensor > Component Information > Locations > Page 3924

Monitoring System (TPMS) Sensor Training
Training
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Wheels and
Tires/Tire Monitoring System/Testing and Inspection/Programming and Relearning.
illuminate.
position.
position.
successfully.
vehicle doors open.

repeated.
Activation
stem.
vehicle doors open.
Chart in Diagnosis and Testing. See: Wheels and Tires/Tire Monitoring System/Testing and
Inspection/Symptom Related Diagnostic Procedures
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal
1. Loosen the 3 upper strut mount nuts 5 turns.
4. Remove the brake hose retainer clip.
5. NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly
aside.
- Support the caliper assembly using mechanic's wire.
6. Remove the brake disc.
7. Remove the wheel speed sensor bolt and position the sensor aside.
8. NOTICE: Leave the tie-rod end nut in place or damage to the tie-rod end may occur.
Loosen the tie-rod end nut.
9. Using the Ball Joint Separator and Adapter, disconnect the tie-rod end from the wheel knuckle.
- Remove and discard the tie-rod end nut.

10. NOTE: Use the hex-holding feature when removing or installing the lower ball joint nut.
Remove and discard the ball joint nut.
11. 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.
Using the Ball Joint Separator and Adapter, separate the ball joint from the wheel knuckle.
12. NOTICE: The inner Constant Velocity (CV) joint must not be bent more than 18 degrees and
the outer CV joint must not be bent more
than 45 degrees or damage to the halfshaft may occur.
Using the Front Wheel Hub Remover, press out the halfshaft from the wheel hub and detach the
halfshaft from the wheel hub.
- Support the halfshaft.
13. Remove and discard the wheel knuckle-to-strut bolt.
14. Remove the wheel knuckle.
Installation
Position the wheel knuckle and install a new wheel knuckle-to-strut bolt.
2. Insert the halfshaft into the wheel hub.
Insert the ball joint into the lower arm and install a new nut.
4. Attach the tie-rod end to the wheel knuckle and install a new nut.
5. Position the wheel speed sensor and install the bolt.
6. Install the brake disc.
7. Position the caliper and anchor plate assembly and install the 2 bolts.
8. Install the brake hose retainer clip.
9. Tighten the 3 upper strut mount nuts to 25 Nm (18 lb-ft).
10. Using the Halfshaft Installer, install the halfshaft into the wheel hub.
11. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be
tightened to specification before the vehicle
is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with
the weight of the vehicle applied.
Install the new wheel hub nut. -
Tighten to 280 Nm (207 lb-ft) in a continuous rotation.
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Power Steering Bleeding: Service and Repair
Power Steering System Purging
NOTICE: If the air is not purged from the power steering system correctly, premature power
steering pump failure may result. The condition may occur on pre-delivery vehicles with evidence of
aerated fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The
power steering purge procedure must be carried out
prior to any component repair for which power steering noise complaints are accompanied by
evidence of aerated fluid.
Remove the power steering reservoir cap. Check the fluid.
2. Raise the front wheels off the floor.
3. Tightly insert the Power Steering Evacuation Cap into the reservoir and connect the Vacuum
Pump Kit.
4. Start the engine.
5. Using the Vacuum Pump Kit, apply vacuum and maintain the maximum vacuum of 68-85 kPa
(20-25 in-Hg).
- If the Vacuum Pump Kit does not maintain vacuum, check the power steering system for leaks
before proceeding. For additional information, refer to Power Steering Fluid Leak Test. See:
Testing and Inspection/Component Tests and General Diagnostics/Steering System/Power
Steering Fluid Leak Test
6. If equipped with Hydro-Boost(R), apply the brake pedal 4 times.
7. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time.
Damage to the power steering pump may
occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
8. Stop the engine.
9. Release the vacuum and remove the Vacuum Pump Kit and the Power Steering Evacuation
Cap.
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
10. NOTE: Do not overfill the reservoir.
Fill the reservoir as needed with the specified fluid.
11. Start the engine.
12. Install the Power Steering Evacuation Cap and the Vacuum Pump Kit. Apply and maintain the
maximum vacuum of 68-85 kPa (20-25 in-Hg).
13. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time.
Damage to the power steering pump may
occur.
Cycle the steering wheel fully from stop-to-stop 10 times.
14. Stop the engine, release the vacuum and remove the Vacuum Pump Kit and the Power
Steering Evacuation Cap.
15. NOTE: Do not overfill the reservoir.
Fill the reservoir as needed with the specified fluid and install the reservoir cap.
16. Visually inspect the power steering system for leaks.

Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Power Steering Fluid: Capacity Specifications
Power Steering Fluid Capacity
Fill between the MIN and MAX lines on reservoir

Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Power Steering Fluid: Fluid Type Specifications
POWER STEERING FLUID
Ford Part Name - Motorcraft MERCON V ATF
Ford Part Number - XT-5-QM
Ford Specification - MERCON V

Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Power Steering Fluid Cooler: Service and Repair
Power Steering Fluid Cooler
2. Disconnect the return hose from the power steering fluid reservoir.
3. Remove the 4 retainers and the lower radiator sight shield.
4. Detach the pressure and return line retainer from the pressure line and return hose.
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
6. Remove the 2 bolts and the power steering cooler.
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Power Steering Fluid Reservoir: Service and Repair
Power Steering Fluid Reservoir
foreign material, or failure of the power steering components may result.
may occur.
1. Using a suitable suction device, remove the power steering fluid from the reservoir.
2. Release the clamp and disconnect the return hose from the power steering fluid reservoir.
3. Remove the 2 power steering fluid reservoir bolts.
4. NOTICE: Use a slight twisting motion when removing the reservoir and carefully pull it away from
the power steering pump on the same
axis as the reservoir outlet tube to avoid damaging the reservoir.
Remove the power steering fluid reservoir.
5. NOTICE: Whenever the power steering fluid reservoir is separated from the power steering
pump, new O-ring seals must be installed or
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
a fluid leak may occur.
Remove and discard the 2 O-ring seals.
6. NOTICE: When installing the power steering fluid reservoir, lubricate the O-rings with the
specified fluid and align the outlet tube of the
reservoir on the same axis as the inlet hole of the power steering pump, or damage to the O-ring
seals may occur.
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose
Power Steering Line/Hose: Service and Repair Steering Gear To Fluid Cooler Return Hose
Steering Gear to Fluid Cooler Return Hose
foreign material or failure of the power
Component Information > Service and Repair > Steering Gear To Fluid Cooler Return Hose > Page 3961
steering components may result.
may occur.
7. Detach the 2 oil pressure sending unit harness clips from the return hose.
10. Remove the return hose.
11. NOTE: Make sure the return hose is routed correctly.
- Install 2 new O-ring seals.
Power Steering Line/Hose: Service and Repair Power Steering Pump To Steering Gear Pressure
Line
Power Steering Pump to Steering Gear Pressure Line

may occur.
Pump Pulley See: Power Steering Pump/Service and
Repair/Power Steering Pump Pulley.
4. Disconnect the Power Steering Pressure (PSP) sensor electrical connector.
5. Remove the PSP sensor from the pressure line.

7. Remove the pressure line bracket from the A/C compressor stud.
- Detach the wiring harness pin-type retainer from the bracket.
- Remove the pressure line-to-A/C compressor stud nut. -
8. Detach the oil pressure sending unit wiring harness retainer from the pressure line
bracket-to-starter stud.
9. Remove the nut from the pressure line bracket-to-starter stud and position the pressure line
bracket aside.

14. Remove the pressure line.
16. NOTE: Make sure the pressure line is routed correctly.

Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
Power Steering Pump
foreign material or failure of the power steering components may occur.
Information > Service and Repair > Power Steering Pump > Page 3969
may occur.
1. With a suitable suction device, remove the power steering fluid from the fluid reservoir.
Pump Pulley See: Power Steering Pump Pulley.
4. Release the clamp and disconnect the return hose from the power steering pump.
5. Remove the 4 bolts and the power steering pump and fluid reservoir.
7. NOTICE: Use a slight twisting motion when removing the reservoir and carefully pull it away from
the pump on the same axis as the
reservoir outlet tube to avoid damaging the reservoir.
NOTICE: Whenever the fluid reservoir is separated from the pump, new O-ring seals must be
installed or a fluid leak may occur.
If necessary, remove the power steering fluid reservoir from the power steering pump and discard
the O-ring seals.
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Power Steering Pump Pulley
Removal
foreign material, or failure of the power steering components may result.
3. Rotate the accessory drive belt tensioner clockwise and position the accessory drive belt away
from the power steering pump pulley.
4. Using the Power Steering Pump Pulley Remover, remove the power steering pump pulley.
Installation
1. NOTE: Make sure the pulley is flush with the end of the power steering pump shaft.
Using the Power Steering Pump Pulley Installer, install the power steering pump pulley.
2. Rotate the tensioner clockwise and position the accessory drive belt on the power steering pump
pulley.
3. Position the accessory drive belt splash shield and install the 2 bolts.

Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations
Pressure Switch > Component Information > Locations > Page 3976

Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch
Switch
Typical PSP Switch

Pressure Switch > Component Information > Description and Operation > Power Steering Pressure (PSP) Switch > Page
3979
Sensor
parking maneuvers.
Typical PSP Sensor

Pressure Switch > Component Information > Description and Operation > Page 3980

Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor

Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Locations
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >

Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering

to Battery.
System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page
3994
3995
Deactivation
latches.
impact sensor(s).
to Battery.

3996
connectors.

Reactivation
refer to Battery.
3997
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Steering Gear
Steering Gear: Service and Repair Steering Gear
Steering Gear
Repair > Steering Gear > Page 4002
Removal
NOTICE: Steering fasteners are critical parts because they affect performance of vital components
and systems and their failure may result in major service expense. New parts must be installed with
the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during
reassembly to make sure of correct retention of these parts.
1. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
2. Remove the stabilizer bar. For additional information, refer to Front Suspension &/or Steering
Knuckle.
3. NOTE: Use the hex-holding feature to prevent turning of the stud while removing the nut.
Remove and discard the 2 outer tie-rod end nuts.
4. Using the Ball Joint Separator and Adapter, disconnect the outer tie-rod ends from the wheel
knuckles.
5. Remove the steering line-to-steering gear retainer bolt and the retainer.
- Remove the steering line clamp plate bolt and rotate the clamp plate.
9. Pull out on the dash seal tabs and push the dash seal upward to detach it from the steering gear.
- Position the dash seal aside.
10. Remove the bolt and disconnect the lower steering column shaft from the steering gear.
- Discard the bolt.
11. Remove the 2 steering gear bolts and the steering gear.
Installation
1. NOTICE: New O-ring seals must be installed any time the pressure and return lines are
disconnected from the steering gear or a fluid
leak may occur.
Install 2 new O-ring seals on the pressure and return lines.
2. Position the steering gear and install the 2 bolts.
3. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of
vehicle control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Connect the lower steering column shaft to the steering gear and install the new bolt. -
4. Install the dash seal to the steering gear.
- Center the dash seal on the steering gear and pull down to attach it to the steering gear.
5. Position the steering gear heat shield and install the 2 bolts.
6. Install the pressure and return lines to the steering gear, rotate the steering line clamp plate and
install the bolt.
7. Position the steering line retainer and install the bolt.
8. Install the stabilizer bar. For additional information, refer to Front Suspension &/or Steering
Knuckle.
9. WARNING: Do not reuse a tie rod-to-wheel knuckle nut. This can result in nut failure and loss of
steering control. Failure to follow this
Position the outer tie-rod ends in the wheel knuckles and install the 2 new nuts.
11. Check and, if necessary, adjust the front toe. For additional information, refer to Suspension
&/or Alignment.
Steering Gear: Service and Repair Steering Gear Boot
Steering Gear Boot
NOTICE: The steering gear boots and clamps are designed to produce an airtight seal and protect
the internal components of the steering gear. If the seal is not airtight, the vacuum generated
during turning will draw water and contamination into the gear, causing damage. Zip ties do not
provide an airtight seal and must not be used.
NOTICE: The inner tie-rod ball joint grease is not compatible with water. Water trapped in the
grease will damage the joint.
1. Remove the outer tie-rod end. For additional information, refer to Tie Rod - Outer See: Tie
Rod/Service and Repair/Tie Rod - Outer.
2. Remove the tie-rod jam nut from the inner tie rod.
3. Remove the steering gear bellows boot.
1. Remove and discard the clamps.
2. Remove the boot.

4. NOTE: Apply the specified grease to the steering gear-to-bellows boot mating surfaces and the
groove in the inner tie rod casting.
NOTE: Make sure the tie rod is clean before installing the boot.
NOTE: Install new inner and outer bellows boot clamps.
- Use Boot Clamp Pliers to tighten the inner steering gear boot clamp.
5. Check and, if necessary, adjust the front toe. For additional information, refer to Suspension &/or
Alignment.
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations
Steering Wheel: Locations
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Locations >
Page 4010
Steering Wheel: Diagrams
Page 4011
Page 4012
Steering Wheel: Service and Repair
Steering Wheel
NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence that the steering column
has rotated, the clockspring must be removed and recentered. For additional information, refer to
Restraint Systems.
2. Turn the steering wheel to the straight-ahead position and turn the ignition switch to the OFF
position.
3. If equipped, disconnect the steering wheel switches electrical connector.
4. Remove the steering wheel bolt.
5. Remove the steering wheel.
6. Tape the clockspring center rotor to the outer housing to keep it from rotating.
Page 4013

Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair >
Tie Rod - Outer
Tie Rod: Service and Repair Tie Rod - Outer
Tie Rod - Outer
2. Loosen the tie-rod jam nut.
3. NOTE: Use the hex-holding feature to prevent turning of the stud while removing the nut.
Remove and discard the outer tie-rod end nut.
- To install, tighten a new nut to 47 Nm (35 lb-ft).
4. Using the Ball Joint Separator and Adapter, disconnect the outer tie-rod end from the wheel
knuckle.
Tie Rod - Outer > Page 4018
5. NOTE: Note the number of turns required to remove the outer tie-rod end for reference during
assembly.
Remove the outer tie-rod end.
6. WARNING: Do not reuse a tie rod-to-wheel knuckle nut. This can result in nut failure and loss of
steering control. Failure to follow this
Alignment.
Tie Rod: Service and Repair Tie Rod - Inner
Tie Rod - Inner
Removal
1. NOTICE: When servicing inner tie rods, a new bellows boot and clamps must be installed. 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: The ball stud housing of an OEM inner tie rod is a rounded design and has no flat surfaces
to accommodate the use of a wrench. The ball stud housing of a replacement inner tie rod is
designed with flat surfaces.
NOTE: If the RH inner tie rod is being serviced, the LH outer tie-rod end and bellows boot must
also be removed to access and hold the steering gear rack when loosening and tightening the inner
tie rod.
Remove the outer tie rod(s). For additional information, refer to Tie Rod - Outer See: Tie Rod -
Outer.
2. Remove the tie-rod jam nut(s) from the inner tie rod.
3. Remove and discard the inner and outer bellows boot clamps.
4. Remove and discard the bellows boot(s).

5. NOTICE: The steering gear rack must be held while loosening or tightening the inner tie rod or
damage to the steering gear may occur.
Place the steering gear at the center position. Use an appropriate-sized wrench on the flat/teeth of
the rack to resist rotation and to prevent damage during removal of the inner tie rod.
NOTE: An assistant will be needed to hold the steering gear rack on the LH side when servicing
the RH inner tie rod.
NOTE: Set screw style inner tie-rod tool shown.
While holding the steering gear rack, use a suitable set screw style inner tie-rod tool to remove the
inner tie rod.
Installation
1. NOTICE: The steering gear rack must be held while loosening or tightening the inner tie rod or
damage to the steering gear may occur.
Place the steering gear at the center position. Use an appropriate-sized wrench on the flat/teeth of
the rack to resist rotation and to prevent damage during removal of the inner tie rod.
NOTE: An assistant will be needed to hold the steering gear rack on the LH side when servicing
the RH inner tie-rod.
NOTE: Crowfoot style inner tie-rod tool shown.
While holding the steering gear rack, use a suitable crowfoot style inner tie-rod tool, or an
appropriate-sized crowfoot wrench to install the inner tie rod.
2. Apply the specified grease to the steering gear-to-bellows boot mating surfaces and bellows boot
grooves in the inner tie-rod casting.
3. NOTE: Make sure the steering gear bellows is positioned correctly over the steering gear
housing bead and the grooves in the inner tie-rod
casting.
NOTE: Make sure the steering gear bellows is not twisted and the vent tube (if equipped) is
securely inserted into the vent nipple of the steering gear bellows.
Position the new inner bellows boot clamp(s) on the new bellows boot(s) and install the bellows
boot(s).
4. NOTICE: Make sure that the end of the steering gear bellows boot is positioned between the 2
grooves on the inner tie rod or an internal
leak may occur.
Using the Boot Clamp Pliers, tighten the inner bellows boot clamp(s).
5. Install the new outer bellows boot clamp(s).
6. Thread the tie-rod jam nut(s) onto the inner tie rod(s).
7. Install the outer tie-rod end(s). For additional information, refer to Tie Rod - Outer See: Tie Rod -
Outer.
Alignment.
Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and
Repair
Axle Beam: Service and Repair
Axle
NOTE: RH side shown, LH side similar
Removal
1. Remove the wheels and tires. For additional information, refer to Wheels and Tires.
2. Secure the brake drum, wheel spindle and backing plate assemblies using mechanic's wire.
Remove and discard the 8 wheel spindle bolts.
3. NOTICE: Use a strap to secure the axle to the jack. Failure to follow this instruction may result in
damage to vehicle components.
Using a suitable transmission jack, support the rear axle.
4. Remove and discard the 2 shock absorber lower nuts and bolts and detach the shock absorbers
from the axle.
5. 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.
NOTICE: Do not hold the stabilizer bar link boot with any tool or damage to the boot may occur.
NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing
the stabilizer bar link nut.
Remove and discard the 2 stabilizer bar link lower nuts and detach the links from the axle.
6. Remove and discard the 8 U-bolt nuts and 4 U-bolts.

Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and
Repair > Page 4026
- Remove the axle.
Installation
NOTICE: Do not tighten the suspension fasteners until the installation procedure is complete and
the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and
bushing damage may occur.
1. NOTICE: Use a suitable strap to secure the axle to the jack. Failure to follow this instruction may
result in damage to vehicle
components.
Using the transmission jack, position the axle and install the 4 U-bolts and 8 nuts.
- Tighten the nuts until snug.
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: Use the hex-holding feature to prevent the ball stud from turning while removing or installing
the stabilizer bar link nut.
Attach the stabilizer bar links to the axle and loosely install the 2 stabilizer bar link lower nuts.
3. Position the shock absorbers and loosely install the 2 shock absorber lower bolts and nuts.
4. Position the brake drum, wheel spindle and backing plate assemblies and install the 8 new
wheel spindle bolts.
- Tighten the bolts to 120 Nm (89 lb-ft).
5. Remove the strap and jack.
6. Install the wheels and tires. For additional information, refer to Wheels and Tires.
7. Lower the vehicle until the weight of the vehicle is resting on the wheels and tires (curb height).
8. NOTE: Tighten the U-bolt nuts evenly in an cross-type pattern.
Tighten the U-bolt nuts to 125 Nm (92 lb-ft).
9. Tighten the stabilizer bar link lower nuts to 100 Nm (74 lb-ft).
10. Tighten the shock absorber lower bolts to 85 Nm (63 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications
Ball Joint: Specifications
Ball Joint Deflection
Lower ball joint......................................................................................................................................

................................................0-0.2 mm (0-0.008 in)
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair
Control Arm: Service and Repair
Lower Arm
Removal
2. Remove and discard the ball joint nut.
3. NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or
damage to the ball joint seal may occur.
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Page 4033
Using the Ball Joint Separator and Adapter, separate the lower arm from the ball joint stud.
4. Remove and discard the lower arm bracket inboard and outboard nuts and bolts.
5. Remove and discard the lower arm forward nut and bolt.
- Remove the lower arm.
Installation
1. NOTICE: To prevent incorrect clamp load or component damage, install the fasteners in their
original orientation. Install the lower arm
bushing clamp bolts with their heads facing down.
NOTE: Do not tighten the nuts and bolts at this time.
Position the lower arm and loosely install the forward bolt and nut.
2. Loosely install the lower arm bracket inboard and outboard bolts and nuts.
3. Position the ball joint into the lower arm and install the ball joint nut.
5. Lower the hoist so the weight of the vehicle is resting on the wheels and tires.
6. Tighten the lower arm forward nut to 190 Nm (140 lb-ft).
7. Tighten the lower arm bracket inboard nut to 240 Nm (178 lb-ft).
8. Tighten the lower arm bracket outboard nut to 100 Nm (74 lb-ft).
9. Check and, if necessary, align the front end. For additional information, refer to Suspension &/or
Alignment.
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Wheel Knuckle
Removal
1. Loosen the 3 upper strut mount nuts 5 turns.
4. Remove the brake hose retainer clip.
5. NOTICE: Do not allow the brake caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly
aside.
- Support the caliper assembly using mechanic's wire.
6. Remove the brake disc.
7. Remove the wheel speed sensor bolt and position the sensor aside.
8. NOTICE: Leave the tie-rod end nut in place or damage to the tie-rod end may occur.
Loosen the tie-rod end nut.
9. Using the Ball Joint Separator and Adapter, disconnect the tie-rod end from the wheel knuckle.
- Remove and discard the tie-rod end nut.

Remove and discard the ball joint nut.
11. 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.
Using the Ball Joint Separator and Adapter, separate the ball joint from the wheel knuckle.
12. NOTICE: The inner Constant Velocity (CV) joint must not be bent more than 18 degrees and
the outer CV joint must not be bent more
Using the Front Wheel Hub Remover, press out the halfshaft from the wheel hub and detach the
halfshaft from the wheel hub.
- Support the halfshaft.
13. Remove and discard the wheel knuckle-to-strut bolt.
14. Remove the wheel knuckle.
Installation
Position the wheel knuckle and install a new wheel knuckle-to-strut bolt.
2. Insert the halfshaft into the wheel hub.
Insert the ball joint into the lower arm and install a new nut.
4. Attach the tie-rod end to the wheel knuckle and install a new nut.
5. Position the wheel speed sensor and install the bolt.
6. Install the brake disc.
7. Position the caliper and anchor plate assembly and install the 2 bolts.
8. Install the brake hose retainer clip.
9. Tighten the 3 upper strut mount nuts to 25 Nm (18 lb-ft).
10. Using the Halfshaft Installer, install the halfshaft into the wheel hub.
11. NOTICE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be
tightened to specification before the vehicle
is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with
the weight of the vehicle applied.
Install the new wheel hub nut. -
Tighten to 280 Nm (207 lb-ft) in a continuous rotation.
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle

Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair
Spindle: Service and Repair
Wheel Spindle
1. Remove the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing
and Wheel Hub See: Wheel Bearing/Service and
Repair/Rear Suspension.
2. Remove the wheel speed sensor bolt and position the wheel speed sensor aside.
- To install, tighten the bolt to 9 Nm (80 lb-in).
3. Remove the 4 wheel spindle bolts and the wheel spindle.
- Discard the bolts.
- To install, tighten the new bolts to 120 Nm (89 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Stabilizer Bushing: Service and Repair
Stabilizer Bar Bushing
Removal
NOTICE: When installing the stabilizer bar bushings, make sure the bushings are correctly oriented
with the bushing flanges in the up position and the bushing split pointing to the front of the vehicle.
2. Remove the 2 stabilizer bar bushing bracket bolts, RH heat shield and the brackets.
- Discard the bolts.
3. NOTE: Inspect the stabilizer bar bushing for wear. If necessary, install a new part.
Remove the stabilizer bar bushing.
Installation
1. NOTICE: The stabilizer bar bushings must be positioned correctly on the flats of the stabilizer
bar or damage to the bushings may occur.
NOTICE: Do not apply any type of lubricant to the stabilizer bar or bushings or damage to the
bushings may occur.
Install the stabilizer bar bushing as shown.

Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
2. NOTICE: Make sure that the stabilizer bar brackets are installed with the rounded bolt tab edge
of the bracket facing towards the front
of the vehicle or damage to the bushings may occur.
NOTICE: Make sure that the stabilizer bar bushing remains in the correct position while positioning
the bracket and installing the bolt or damage to the bushings may occur.
Position the stabilizer bar bracket and install the 2 new bolts and the RH heat shield.
- Tighten alternately and evenly to 70 Nm (52 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Service and Repair > Front Suspension
Stabilizer Link: Service and Repair Front Suspension
Stabilizer Bar Link
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.
2. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or
installing the stabilizer bar link nuts.
Remove and discard the stabilizer bar link upper and lower nuts.
- To install tighten the new nuts to 50 Nm (37 lb-ft).
3. Remove the stabilizer bar link.

Component Information > Service and Repair > Front Suspension > Page 4057
Stabilizer Link: Service and Repair Rear Suspension
Stabilizer Bar and Link
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.
installing the stabilizer bar link nut.
Remove and discard the 2 stabilizer bar link lower nuts.
- To install, tighten the new nuts to 100 Nm (74 lb-ft).
3. NOTE: If removing the stabilizer bar links only, proceed to Step 4.
Remove and discard the 4 stabilizer bar bracket bolts. Remove the stabilizer bar brackets and
stabilizer bar.
- To install tighten the new bolts to 70 Nm (52 lb-ft).
installing the stabilizer bar link nut.
Component Information > Service and Repair > Front Suspension > Page 4058
Remove and discard the 2 stabilizer bar link upper nuts.
- To install tighten the new nuts to 100 Nm (74 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information >
Specifications
Front Subframe: Specifications
SPECIFICATIONS
Front Subframe: Description and Operation
Subframe and Mounting Systems
The front subframe is bolted to the body and is used to:
- aid in structural support.
- provide mounting surfaces for the steering gear.
- provide mounting surfaces for the front suspension lower control arms, the engine mounts and for
the front stabilizer bar.
For body dimension specifications, refer to Specifications / Dimensions.

Front Subframe: Service and Repair
Subframe - Front
NOTE: The front bumper cover and the RH/LH brake assemblies have been removed for clarity.
Removal
1. Center the steering wheel, remove the ignition key and lock the steering wheel in position.
2. Disconnect the steering column shaft from the steering column coupling shaft.
- Discard the bolt.
3. Remove the front wheels and tires. For additional information, refer to Wheels and Tires.
4. NOTICE: Leave the tie-rod end nuts in place to protect the ball joint studs or damage to the
vehicle may occur.
Loosen, but do not remove, the tie-rod end nut on both sides.
5. Using the Tie-Rod End Remover, disconnect the tie-rod end from the wheel knuckle on both
sides.
- Remove the tie-rod end nuts.
6. Remove the stabilizer bar link nuts on both sides and position the stabilizer bar links and ABS
wiring brackets aside.
7. Remove the power steering line retainer bolt and retainer from the steering gear.
8. Remove the power steering line clamp clockwise, and disconnect the 2 power steering lines from
the power steering gear.
- Allow the remaining oil to drain into a suitable container.
9. Remove the roll restrictor bolt.
10. Using a suitable support table, support the front subframe.
11. Index-mark the location of the subframe to the vehicle before removal.
12. NOTE: Separate the ball joint from the wheel knuckle as the front subframe is lowered.
Disconnect the lower arm ball joint from the wheel knuckle on both sides.
- Remove the 2 lower arm ball joint heat shields.
13. Remove the 6 subframe bolts.
14. Remove the front subframe.
Installation
1. Position the subframe to the vehicle.
2. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.
Loosely install the 6 subframe lower bolts.
- Align the index marks made before removal.
- Tighten the front subframe bolts to 125 Nm (93 lb-ft).
- Tighten the rear subframe bolts to 200 Nm (148 lb-ft).
3. Remove the support table.
4. Install the roll restrictor bolt.
5. Position the lower arm ball joint to the wheel knuckle on both sides and install the nuts.
6. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
Using the Teflon(R) Seal Installer Set, install new O-ring seals onto the power steering lines.
7. Connect the power steering lines to the power steering gear, rotate the power steering line
clamp counterclockwise and loosely install the bolt.
8. Install the power steering line retainer and bolt.
9. Tighten the power steering line clamp bolt to 18 Nm (159 lb-in).
10. Install the 2 stabilizer bar links, ABS wiring brackets and the nuts.

11. WARNING: Do not reuse a tie rod-to-wheel knuckle nut. This can result in nut failure and loss
of steering control. Failure to follow this
Install the 2 tie-rod ends and the nuts. -
12. Install the front wheels and tires. For additional information, refer to Wheels and Tires.
13. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss
of vehicle control. Failure to follow this
Connect the steering column shaft to the steering column coupling shaft and install the bolt. -
14. Fill and bleed the power steering system. For additional information, refer to Steering.
15. Check the front end alignment and adjust as necessary. For additional information, refer to
Suspension &/or Alignment.
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Removal and Replacement
Suspension Spring ( Coil / Leaf ): Removal and Replacement
Front Suspension
Strut and Spring Assembly
2. Detach the brake hose from the support bracket.
3. Remove the stabilizer bar link upper nut and detach the link from the strut.
Remove the wheel knuckle-to-strut bolt.
- Stage 1: To install, tighten to 100 Nm (74 lb-ft).

Information > Service and Repair > Removal and Replacement > Page 4071
5. NOTICE: The inner Constant Velocity (CV) joint must not be bent more than 18 degrees and the
outer CV joint must not be bent more
Detach the wheel knuckle from the strut and spring assembly.
- Support the wheel knuckle and halfshaft using mechanic's wire.
6. NOTICE: Support the strut and spring assembly to prevent damage.
Remove the upper strut mount nuts and the strut and spring assembly.
- For additional information on the disassembly and assembly of the strut and spring assembly,
refer to Strut and Spring Assembly See: Suspension Strut / Shock Absorber/Service and
Repair/Overhaul.
Alignment.
Rear Suspension
Spring
Removal
2. Using a suitable jack, support the rear axle.
3. Remove and discard the shock absorber lower nut and bolt.
4. Remove the 4 U-bolt nuts, the 2 U-bolts and the U-bolt guide plate.
- Discard the U-bolts and nuts.
5. Remove and discard the body bracket-to-spring bolt and nut.
6. Remove and discard the shackle-to-body nut and bolt.

7. NOTICE: To avoid damage to the brake hose, make sure the axle is only lowered enough to
allow for removal of the spring.
Lower the jack and remove the spring.
8. Remove the shackle-to-spring nut, bolt and shackle.
- Discard the bolt and nut.
Installation
NOTICE: Do not tighten the suspension fasteners until the installation procedure is complete and
the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and
bushing damage may occur.
1. Inspect the inner and outer body bushings and install new bushings as necessary.
2. Position the shackle and install the new shackle-to-spring nut and bolt.
- Tighten the nut until snug.
3. Using a suitable jack, support the rear axle.
4. Position the spring and install the body bracket-to spring bolt and nut.

5. Install the new shackle-to-body bolt and nut.
6. Position the U-bolt guide plate and install the 2 new U-bolts and 4 new nuts.
- Tighten until snug.
7. Install the new shock absorber lower nut and bolt.
- Tighten until snug.
8. Lower and remove the jack.
10. Lower the vehicle until the weight of the vehicle is resting on the wheels and tires (curb height).
11. Tighten the shackle-to-body nut to 115 Nm (85 lb-ft).
12. Tighten the body bracket-to-spring nut to 150 Nm (111 lb-ft).
13. Tighten the shackle-to-spring nut to 115 Nm (85 lb-ft).
14. NOTE: Tighten the U-bolt nuts evenly in a cross-type pattern.
Tighten the U-bolts nuts to 125 Nm (92 lb-ft).
15. Tighten the shock absorber lower nut to 85 Nm (63 lb-ft).

Suspension Spring ( Coil / Leaf ): Overhaul
Disassembly and Assembly
components and systems and their failure can result in major service expense. A new part with the
same part number must be installed if installation is necessary. Do not use a new part of lesser
quality or substitute design. Torque values must be used as specified during reassembly to make
sure of correct retention of these parts.
1. Remove the strut and spring assembly. For additional information, refer to Strut and Spring
Assembly See: Suspension Strut / Shock
Absorber/Service and Repair/Removal and Replacement/Front Suspension.
2. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to
follow this instruction may result in serious personal injury.
Using a suitable coil spring compressor, compress the spring.
3. NOTE: Use the hex-holding feature to prevent the strut rod from rotating while removing the nut.
Remove and discard the strut rod nut.
4. Remove the upper strut mount, spring upper seat and dust boot.
5. Remove the strut and jounce bumper.
6. Carefully remove the spring from the spring compressor.
7. NOTICE: Make sure the upper strut mount is correctly seated before assembly or damage to the
upper mount may occur.
To assemble, reverse the disassembly procedure.

Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Removal and Replacement
Suspension Strut / Shock Absorber: Removal and Replacement
Front Suspension
2. Detach the brake hose from the support bracket.
3. Remove the stabilizer bar link upper nut and detach the link from the strut.
Remove the wheel knuckle-to-strut bolt.
- Stage 1: To install, tighten to 100 Nm (74 lb-ft).

5. NOTICE: The inner Constant Velocity (CV) joint must not be bent more than 18 degrees and the
outer CV joint must not be bent more
Detach the wheel knuckle from the strut and spring assembly.
- Support the wheel knuckle and halfshaft using mechanic's wire.
6. NOTICE: Support the strut and spring assembly to prevent damage.
Remove the upper strut mount nuts and the strut and spring assembly.

- For additional information on the disassembly and assembly of the strut and spring assembly,
refer to Strut and Spring Assembly See: Overhaul.
Alignment.
Rear Suspension
Shock Absorber
Removal
2. Remove and discard the shock absorber lower nut and bolt.
3. Remove and shock absorber upper bolt and the shock absorber.
- Discard the bolt.

Installation
NOTICE: Do not tighten the shock absorber fasteners until the installation procedure is complete
and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load
and bushing damage may occur.
1. Position the shock absorber and loosely install the shock absorber upper bolt.
2. Loosely install shock absorber lower bolt and nut.
3. Lower the vehicle until the weight of the vehicle is resting on the wheels and tires.
4. Tighten the shock absorber upper bolt to 120 Nm (89 lb-ft).
5. Tighten the shock absorber lower bolt to 85 Nm (63 lb-ft).

Suspension Strut / Shock Absorber: Overhaul
Disassembly and Assembly
components and systems and their failure can result in major service expense. A new part with the
same part number must be installed if installation is necessary. Do not use a new part of lesser
quality or substitute design. Torque values must be used as specified during reassembly to make
sure of correct retention of these parts.
1. Remove the strut and spring assembly. For additional information, refer to Strut and Spring
Assembly See: Removal and Replacement/Front
Suspension.
2. WARNING: Keep all body parts clear of shock absorbers or strut rods. Shock absorbers or struts
can extend unassisted. Failure to
follow this instruction may result in serious personal injury.
Using a suitable coil spring compressor, compress the spring.
3. NOTE: Use the hex-holding feature to prevent the strut rod from rotating while removing the nut.
Remove and discard the strut rod nut.
4. Remove the upper strut mount, spring upper seat and dust boot.
5. Remove the strut and jounce bumper.
6. Carefully remove the spring from the spring compressor.
7. NOTICE: Make sure the upper strut mount is correctly seated before assembly or damage to the
upper mount may occur.
To assemble, reverse the disassembly procedure.

Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension

and Repair > Front Suspension > Page 4086
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front
Steering Knuckle/Service and Repair.
wheel hub.
Installation
wheel hub.
4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Front Steering

Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications

to..............................................................................................................................................340 Nm
(251 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Service and Repair
Jacking and Lifting
personal injury.

Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Module > Component Information > Locations
Pressure Module > Component Information > Locations > Page 4101

Removal
damage may result.
to Information Bus.
Installation

System (TPMS) Sensor Training See: Tire Monitoring System/Testing and Inspection/Monitors,
Trips, Drive Cycles and Readiness Codes.
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor
Training
Training
information, refer to Tire Pressure Monitoring System (TPMS) Sensor Activation See: Tire
Monitoring System/Testing and Inspection/Programming and Relearning.
illuminate.
position.
position.
successfully.
vehicle doors open.

Training > Page 4112
repeated.
Training > Page 4113
Activation
stem.
vehicle doors open.
Chart in Diagnosis and Testing. See: Tire Monitoring System/Testing and Inspection/Symptom
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module

Removal
damage may result.
to Information Bus.
Installation

Readiness Codes.
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Training
illuminate.
position.
position.
successfully.
vehicle doors open.

> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page
4128
repeated.
> Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training > Page
4129
Activation
stem.
vehicle doors open.
Procedures
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Front Suspension

Service and Repair > Front Suspension > Page 4134
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle See:
Steering/Front Steering Knuckle/Service and Repair.
wheel hub.
Installation
wheel hub.
4. Install the wheel knuckle. For additional information, refer to Wheel Knuckle See: Steering/Front
Steering Knuckle/Service and Repair.

Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications

to..............................................................................................................................................340 Nm
(251 lb-ft).

Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Tighten the wheel nuts in a star/cross pattern

to............................................................................................................................................90 Nm
(66 lb-ft).
Service and Repair > Front Suspension
Wheel Fastener: Service and Repair Front Suspension
Wheel Studs
Removal
1. NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may
result in major service expense. New parts must be installed with the same part numbers or
equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or
substitute design. Torque values must be used as specified during reassembly to make sure of
correct retention of these parts.
NOTE: Make sure the steering wheel is in the UNLOCKED position.
Remove the brake disc. For additional information, refer to Disc Brake System.
Installation
Position the wheel stud in the flange, making sure the serrations on the stud line up with the
serrations in the flange. Install the washers and a wheel nut.
2. NOTICE: Do not use power tools to install the wheel stud or damage to the flange may occur.
Tighten the wheel nut until the stud is seated against the hub flange.
3. Remove the wheel nut and the washers. Discard the wheel nut.
4. Install the brake disc. For additional information, refer to Disc Brake System.
Wheel Fastener: Service and Repair Rear Suspension
Wheel Studs
NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result.
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made
by the original wheel stud.
- Place approximately 4 washers over the outside end of the wheel stud and thread a standard
wheel nut onto the wheel stud with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub
flange.
4. Remove the wheel nut and washers.
5. Install the brake drum. For additional information, refer to Drum Brake System.
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair
Accumulator HVAC: Service and Repair
Suction Accumulator
4. Remove the suction accumulator outlet fitting nut and disconnect the fitting.
5. Remove the suction accumulator bracket nut.
6. Remove the 2 suction accumulator bolts.
7. Disconnect the suction accumulator outlet fitting.
8. Remove the suction accumulator.

Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Page 4153
- Install new O-ring seals.

Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations
Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Locations >
Page 4157

Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Air Door Actuator / Motor: Locations
Air Door Actuator / Motor: Diagrams
Air Door Actuator / Motor: Service and Repair
Mode Door Actuator - Air Inlet Door
1. Remove the blower motor resistor. For additional information, refer to Blower Motor Resistor
See: Blower Motor Resistor/Service and Repair.
2. Remove the 3 air inlet mode door actuator screws.
3. Disconnect the air inlet mode door actuator electrical connector.
4. Remove the air inlet mode door actuator.

Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC >
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Position Sensor / Switch, HVAC >

Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair
Air Duct: Service and Repair
Air Inlet Duct
1. Remove the heater core and evaporator core housing. For additional information, refer to Heater
Core And Evaporator Core Housing See:
Housing Assembly HVAC/Service and Repair.
2. Remove the floor duct screw and the floor duct.
3. Remove the 2 air inlet duct screws.
4. Remove the 4 air inlet duct clips.
5. Detach and remove the air inlet duct.

Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair
Air Register: Service and Repair
Register
Center Registers
LH Register
RH Register
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Page 4175
Center register
1. Remove the upper center instrument panel finish panel. For additional information, refer to
Instrument Cluster / Carrier &/or Interior Moulding /
Trim.
LH register
2. Remove the LH instrument panel end panel.
RH register
3. Lower the glove compartment.
4. Remove the RH instrument panel end panel.
All registers
5. Release the 3 register retaining tabs and push the register out of the register opening.

Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 10-11-4 > Jun > 10 > A/C - Blower Motor Runs Continuously/Compressor
Inop.
Blower Motor: Customer Interest A/C - Blower Motor Runs Continuously/Compressor Inop.
TSB 10-11-4
06/21/10
CLIMATE CONTROL BLOWER MOTOR - CONTINUOUS OPERATION / INOPERATIVE ON ONE

SPEED - A/C COMPRESSOR INOPERATIVE - BUILT ON OR BEFORE 817/2009
This article supersedes TSB 09-19-6 to add a production fix date, update the Service Procedure
and Service Labor Time Standard.
ISSUE Some 2010 Transit Connect vehicles built on or before 8/7/2009 may exhibit a climate
control blower motor continuously operating, inoperative on one speed setting, or a/c compressor is
inoperative. This may be due to a wire chafe behind the center console.
SERVICE PROCEDURE
If the climate control blower motor continuously operates or is inoperative on one speed setting,
proceed to Step 3.
If A/C compressor is inoperative, proceed to Step 1. The instrument cluster (IC) sends the climate
control blower motor ON signal to the Generic Electronic Module (GEM). If the climate control
blower motor ON signal is not received by the GEM, A/C compressor is not enabled.
1. Connect IDS scan tool.
2. Select active command to turn on the A/C compressor.

a. If the A/C compressor engages, proceed to Step 3.
b. If the A/C compressor did not engage, proceed with normal diagnostics. Refer to the Workshop
Manual, Section 412-00.
6. Confirm touch condition between blower motor switch wiring and instrument panel (IP) bracket.
(Figure 1)
Inop. > Page 4184
7. Repair any chafed wires using Ford approved splicing methods. Refer to Wiring Diagram (WD),
Cell 5.
8. Pull the climate control blower motor wiring away from the IP bracket and secure to the large
bundle of wire. (Figures 2 and 3)
9. Tighten tie strap and verify blower motor wiring has sufficient clearance from the IP bracket.
(Figure 4)
10. Install selector lever trim panel.
Inspect And Repair Wire Harness Includes Time For Diagnosis In This Article
Inop. > Page 4185
(Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > Customer Interest for Blower Motor: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't Turn OFF/One Speed
Inop.
Blower Motor: Customer Interest A/C - Blower Motor Won't Turn OFF/One Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
Inop. > Page 4190
(Figures 2 and 3)
(Figure 4)
Labor Operations)
Inop. > Page 4191
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > All Technical Service Bulletins for Blower Motor: > 10-11-4 > Jun > 10 > A/C - Blower Motor Runs
Continuously/Compressor Inop.
Blower Motor: All Technical Service Bulletins A/C - Blower Motor Runs Continuously/Compressor
Inop.
TSB 10-11-4
06/21/10

SERVICE PROCEDURE
proceed to Step 3.

(Figure 1)
Continuously/Compressor Inop. > Page 4197
Cell 5.
(Figure 4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > All Technical Service Bulletins for Blower Motor: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't Turn OFF/One
Speed Inop.
Blower Motor: All Technical Service Bulletins A/C - Blower Motor Won't Turn OFF/One Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
Speed Inop. > Page 4203
(Figures 2 and 3)
(Figure 4)
Labor Operations)
Speed Inop. > Page 4204
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > Page 4205
Blower Motor: Locations
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Blower Motor: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Blower Motor: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Blower Motor: Connector Views

Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 4228
Blower Motor: Service and Repair
Blower Motor
2. Remove the floor duct screw and the floor duct.
3. Disconnect the blower motor electrical connector.
4. Remove the 3 blower motor screws.
5. Remove the blower motor.

Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations

Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Testing and
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 4240
Blower Motor Resistor: Diagrams
Page 4241
Page 4242
Blower Motor Resistor: Service and Repair
Blower Motor Resistor
1. Lower the glove compartment.
2. Disconnect the blower motor resistor electrical connector.
3. Remove the blower motor resistor.
1. Disconnect the blower motor resistor electrical connector.
2. Remove the blower motor resistor screw.
3. Detach and remove the blower motor resistor.

Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Technical
Service Bulletins > Customer Interest for Blower Motor Switch: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't Turn
OFF/One Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
OFF/One Speed Inop. > Page 4251
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Service Bulletins > All Technical Service Bulletins for Blower Motor Switch: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't
Turn OFF/One Speed Inop.
Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
Turn OFF/One Speed Inop. > Page 4258
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Service Bulletins > Page 4260
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Compressor Clutch: Adjustments
Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C
clutch pulley.
2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers
between the clutch plate hub and the compressor shaft
until the clearance is within specification.

Information > Adjustments > Page 4267
Compressor Clutch: Service and Repair
Clutch and Clutch Field Coil
Removal
1. Remove the A/C compressor. For additional information, refer to Air Conditioning (A/C)
Compressor See: Service and Repair.
2. Remove the A/C clutch disc and hub bolt.
1. Using a suitable spanner-type wrench, hold the A/C clutch disc and hub.
2. Remove the A/C clutch disc and hub bolt.

3. Remove the A/C clutch disc and hub and the spacer(s).
4. Remove the A/C compressor pulley snap ring.
5. NOTICE: Do not use air tools. Damage to the Air Conditioning (A/C) clutch pulley or A/C
compressor may result.
Remove the A/C compressor pulley.
1. Install the A/C Compressor Shaft Protector.

2. Install a suitable 3 jaw puller on the A/C Compressor Shaft Protector and A/C compressor pulley.
3. Remove the A/C compressor pulley.
6. Remove the 4 A/C clutch field coil screws.
7. Remove the A/C clutch field coil.
Installation
NOTE: The A/C clutch components should be reused unless obvious signs of damage are found.
1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for
damage.
- Inspect for physical damage, including cracked or melted components or discoloration due to
excessive heat.
- Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor
pulley that is more than fingernail depth.
- Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Install the A/C clutch field coil.
4. Install the 4 A/C clutch field coil screws.
5. NOTE: The A/C compressor must be positioned on the press so that only the flat part of the A/C
compressor housing is contacting the base with
the A/C compressor shaft aligned with the center of the press shaft. If the A/C compressor is not
installed correctly on the press, the A/C compressor and/or A/C compressor pulley will be
damaged.
Install the A/C compressor pulley.
1. Install the A/C compressor on a suitable press.
2. Position the A/C compressor pulley on the A/C compressor.
3. Install the A/C Clutch Installer on the A/C compressor pulley.
4. Using the press, install the A/C compressor pulley.

6. Install the A/C compressor pulley snap ring with the bevel side out.
7. Install one medium thickness A/C clutch disc and hub spacer inside the clutch hub spline
opening.
8. Install the A/C clutch disc and hub.
9. Install the A/C compressor clutch disc and hub bolt.
1. Hold the A/C clutch disc and hub with a suitable spanner-type wrench.
2. Tighten the bolt to 20 Nm (177 lb-in).
10. Measure and adjust the clutch air gap by removing, replacing or adding A/C clutch disc and hub
spacers.
11. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C)
Compressor See: Service and Repair.
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Compressor Clutch Coil: Locations
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair
Condenser HVAC: Service and Repair
Condenser Core

Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Page 4280
7. Position a suitable jackstand below the lower radiator support to support the cooling module.
NOTE: The cooling module will have to be held in position and the jackstand will have to be
lowered to remove the lower radiator support. The cooling module must then be positioned back
onto the jackstand.
9. Remove the condenser outlet and inlet fitting nuts and disconnect the fitting.
10. Detach the transmission cooler from the condenser core (if equipped).
11. Using a suitable rubber mallet, gently tap the condenser core toward the RH side of the vehicle,
while holding the condenser bracket in-place, to
detach the condenser core from the bracket.
12. Remove the condenser core.

Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
Control Assembly: Locations
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Climate Control Assembly
Control Assembly: Diagrams Climate Control Assembly
> Climate Control Assembly > Page 4286
Control Assembly: Diagrams Function Selector Switch
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Blower Motor Switch
Control Assembly: Service and Repair Blower Motor Switch
Blower Motor Switch
2. Remove the blower motor switch knob.
3. Remove the blower motor switch screw.
4. Rotate the blower motor switch to disengage it from the climate control assembly and remove
the blower motor switch.

and Repair > Blower Motor Switch > Page 4291
Control Assembly: Service and Repair Climate Control Assembly
Climate Control Assembly
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.

and Repair > Blower Motor Switch > Page 4292
Control Assembly: Service and Repair Function Selector Switch
Function Selector Switch
NOTE: The function selector switch is supplied as an assembly with the function selector cable
assembly.
2. Remove the function selector switch knob.
3. Remove the function selector switch screw.
4. Rotate the function selector switch to disengage it from the climate control assembly and remove
the function selector switch and cable assembly.
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair
Expansion Block/Orifice Tube: Service and Repair
Evaporator Core Orifice
Removal
2. Disconnect the evaporator core orifice access fitting.
3. Inspect the evaporator core orifice for damage before attempting to remove it from the line.
4. If the evaporator core orifice is intact, engage the Fixed Orifice Remover/Installer. Hold the
T-handle stationary while rotating the tool body to
remove the evaporator core orifice.
5. If the evaporator core orifice is broken, screw the end of the Broken Orifice Remover into the
broken orifice. Hold the T-handle stationary while
rotating the tool body to remove the evaporator core orifice.

Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Installation
1. Lubricate the evaporator core orifice O-ring seals in clean PAG oil and install the evaporator core
orifice using the Fixed Orifice
Remover/Installer.
2. Connect the evaporator core orifice access fitting.
3. Add the correct amount of clean PAG oil to the refrigerant system.

Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair
Heater Core: Service and Repair
Heater Core
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Page 4300
NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
2. Drain the engine coolant. For additional information, refer to Cooling System &/or Engine Block
Heater.
5. Remove the screw and the floor duct.
6. Release the 2 heater hose clamps and disconnect the heater hoses from the heater core.
7. Remove the 6 in-vehicle crossbeam bracket bolts and remove the brackets (RH shown).
8. Remove the LH floor duct clip between the heater core and evaporator core housing and the
dash panel.
Page 4301
9. Remove the LH floor duct.
1. Remove the LH floor duct clip
2. Remove the LH floor duct screw.
- Remove the LH floor duct.
10. Remove the RH floor duct.
1. Remove the RH floor duct clip.
2. Remove the RH floor duct screw.
- Remove the RH floor duct.
11. Remove the heater core cover.
1. Remove the 2 heater core cover screws.
2. Remove the 2 heater core cover clips.
3. Release the heater core cover tab and remove the heater core cover and heater core as an
assembly.
Page 4302
12. Remove the heater core tube bracket screw.
13. Remove the heater core.
15. Fill the engine coolant level. For additional information, refer to Cooling System &/or Engine
Block Heater.
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Service and Repair
High Pressure Safety Valve HVAC: Service and Repair
Air Conditioning (A/C) Pressure Relief Valve
3. Remove the A/C pressure relief valve.
4. NOTE: A new O-ring seal will already be installed on the new A/C pressure relief valve service
part.

Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> Compressor To Condenser Discharge Line
Hose/Line HVAC: Service and Repair Compressor To Condenser Discharge Line
Compressor to Condenser Discharge Line

> Compressor To Condenser Discharge Line > Page 4310

3. Remove the high-pressure service gauge port valve extension bracket nut.
Position a suitable jackstand below the lower radiator support to support the cooling module.
9. NOTE: The cooling module will have to be held in position and the jackstand will have to be
lowered to remove the lower radiator support. The
cooling module must then be positioned back onto the jackstand.

10. Remove the compressor-to-condenser discharge line bracket nut.
11. Remove the A/C compressor suction fitting nut and disconnect the fitting.
12. Remove the A/C compressor discharge fitting nut and disconnect the fitting.
13. Remove the condenser inlet fitting nut and disconnect the fitting.
14. Remove the compressor-to-condenser discharge line.

Hose/Line HVAC: Service and Repair Condenser To Evaporator Line
Condenser to Evaporator Line

ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Hose/Line HVAC: Service and Repair Evaporator Outlet Line

Evaporator Outlet Line
4. Disconnect the A/C cycling switch electrical connector.
6. Disconnect the suction accumulator inlet fitting.
7. Detach the evaporator outlet line from the 2 line routing clips.
8. Remove the evaporator outlet line.


Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair
Housing Assembly HVAC: Service and Repair
Heater Core And Evaporator Core Housing

Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
Block Heater.
4. Remove the instrument panel. For additional information, refer to Instrument Cluster / Carrier
5. Remove the evaporator drain tube.
6. Release the 2 heater hose clamps and disconnect the 2 heater hoses from the heater core.
7. Remove the 2 Evaporative Emission (EVAP) canister purge valve heat shield pin-type retainers
and position the shield aside.
9. Disconnect the evaporator inlet fitting.
10. Remove the 2 exterior heater core and evaporator core housing nuts.
11. Remove the 2 interior heater core and evaporator core housing nuts.
12. Remove the heater core and evaporator core housing.
- Install new O-ring seals.
14. Fill the engine cooling system. For additional information, refer to Cooling System &/or Engine
Block Heater.

Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
......................................................................................................................................................WS
..............................................................0.841 kg (29.6 oz) (1.85 lb)
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Refrigerant: Fluid Type Specifications
......................................................................................................................................................WS
..............................................................0.841 kg (29.6 oz) (1.85 lb)
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
4325
Refrigerant: Testing and Inspection
Refrigerant Identification Testing
Refrigerant Identification
1. NOTE: A Refrigerant Blend Identifier with Printer must be used to identify gas samples taken
directly from the refrigeration system or storage
containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Refrigerant Blend Identifier with Printer to obtain the
sample for testing.
2. The Refrigerant Blend Identifier with Printer will display one of the following:
- If the purity level of R-134a is 98% or greater by weight, the green PASS LED will light. The
weight concentrations of R-134a, R-12, R-22, hydrocarbons and air will be displayed on the digital
display.
- If refrigerant R-134a does not meet the 98% purity level, the red FAIL LED will light and an alarm
will sound alerting the user of potential hazards. The weight concentrations of R-134a, R-12, R-22
and hydrocarbons will be displayed on the digital display.
- If hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light,
"Hydrocarbon High" will be displayed on the digital display, and an alarm will sound alerting the
user of potential hazards. The weight concentrations of R-134a, R-12, R-22 and hydrocarbons will
also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R-134a content is 98% or
greater. The Refrigerant Blend Identifier with
Printer eliminates the effect of air when determining the refrigerant sample content because air is
not considered a contaminant, although air can affect A/C system performance. When the
Refrigerant Blend Identifier with Printer has determined that a refrigerant source is pure (R-134a is
98% or greater by weight) and air concentration levels are 2% or greater by weight, it will prompt
the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the
refrigerant is indeed contaminated.
Contaminated Refrigerant Handling

NOTICE: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a
recovery/recycling equipment. Recovery of contaminated refrigerant will contaminate the recovered
refrigerant supply and may damage the recovery/recycling equipment.
NOTE: A new suction accumulator or receiver/drier must be installed as directed by the A/C system
flushing procedure.
1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant only.
- If this equipment is not available, contact an A/C service facility in the area with the correct
equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. Flush the A/C system.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local
regulations.
4326
Refrigerant: Service and Repair
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any
vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If
the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C
refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment
manufacturer's procedures and instructions.
NOTICE: On vehicles being serviced for an internal compressor or desiccant failure, a new suction
accumulator or receiver/drier, Thermostatic Expansion Valve (TXV) or evaporator core orifice and
any hoses containing mufflers must be installed prior to filtering the Air Conditioning (A/C) system.
Internal plumbing of these devices makes it impossible to correctly remove any foreign material.
These components are typically discarded after A/C system contamination. Hoses without mufflers
can normally be reused unless they are clogged with foreign material. The filter is intended for use
on one vehicle only.
1. NOTE: The filter inlet is marked with a label on one side of the filter body.
Orient the filter inlet toward the A/C condenser core.
2. NOTICE: The flexible extension adapters included in the A/C Flush Adapter Kit are designed for
low-pressure flushing and are not
designed for use with a charged refrigerant system. Do not make the condenser fitting connections
using the flexible extension adapters or damage to the adapters and loss of refrigerant will occur.
NOTE: The F8VZ-19E773-AB pancake filter is not permanently installed and will be removed at the
end of this procedure.
Disconnect the condenser outlet fitting and temporarily install the pancake filter between the 2
halves of the fitting.
- Use flexible R-134a service hoses of 17,238 kPa (2,500 psi) burst rating.
- Make the connections using the correct adapters from the A/C Flush Adapter Kit and/or A/C Flush
and Purge Fitting Kit.
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Refrigerant Oil Adding See:
Service and Repair/Refrigerant Oil Adding.

4327
4. Evacuate and charge the refrigerant system. For additional information, refer to Air Conditioning
(A/C) System Recovery, Evacuation and
Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
5. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure
they do not interfere with other engine
compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select A/C
operation and set the blower motor speed to maximum.
Start the engine and let it idle briefly. Make sure the A/C system is operating correctly.
7. Using a scan tool, command the idle to gradually bring the engine up to 1,200 rpm by running it
at lower rpms for short periods (first at 800 rpm,
then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C system
operating.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System
Recovery, Evacuation and Charging See: Service and
Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging.
10. Remove the adapters, flexible hoses and pancake filter from between the condenser and the
condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation
and Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Item...............................................................................................................................................Moto
..........................................................................................................................................WSH-M1C2
31-B Fill Capacity.................................................................................................................................
...............................................................180 ml (6.09 fl oz)
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 4332
Refrigerant Oil: Fluid Type Specifications
Item...............................................................................................................................................Moto
..........................................................................................................................................WSH-M1C2
31-B Fill Capacity.................................................................................................................................
...............................................................180 ml (6.09 fl oz)
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
4333
Refrigerant Oil: Service and Repair

NOTE: During normal A/C operation, oil is circulated through the system with the refrigerant, and a
small amount is retained in each component. If certain components of the system are removed,
some of the PAG oil will go with the component. To maintain the original total oil charge, it is
necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Refer to the chart below for refrigerant oil adding amounts and methods of installation.
a If an excessive amount of PAG oil is lost due to a hose rupture/separation or other damage, the
total system PAG oil capacity must be added. b The amount specified may be used for one or
multiple O-ring leak repairs. Do not multiply the PAG oil amount by the number of O-ring leaks
being repaired.
Adding Refrigerant Oil After A/C Compressor Replacement
Service A/C compressors shipped without clutch and pulley
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 oz), pour the
same amount plus 30 ml (1 oz) of clean
4334
PAG Refrigerant Compressor Oil (R-134a Systems) (YN-12-D) WSH M1C231-B or equivalent into
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5 oz),
pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-134a Systems) or
equivalent into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 oz), pour
85 ml (3 oz) of clean A/C Refrigerant Compressor Oil (R-134a Systems) or equivalent into the new
A/C compressor.
Service A/C compressors shipped with clutch and pulley
device.
- If the amount of oil drained from the old A/C compressor is less than 89 ml (3 oz), remove 118 ml
(4 oz) from the new A/C compressor.
- If the amount of oil drained from the old A/C compressor is 89 ml (3 oz), remove 89 ml (3 oz) from
- If the amount of oil drained from the old A/C compressor is greater than 148 ml (5 oz), remove 0
ml (0 oz) from the new A/C compressor.
Adding Refrigerant Oil After New Suction Accumulator or Receiver/Drier Replacement
NOTE: This refrigerant oil adding method is to be used when a new suction accumulator or
receiver drier only has been installed. If a new A/C compressor and evaporator core orifice or
Thermostatic Expansion Valve (TXV) have also been installed due to system contamination, refer
to the appropriate heading.
1. Drill one 12.7 mm (1/2 in) hole in the old suction accumulator or receiver/drier cylinder and drain
the oil into a clean measuring cup.
2. Add the same quantity of new PAG oil, plus the amount collected during refrigerant recovery and
60 ml (2 fl oz).
Adding Refrigerant Oil After Multiple Component Replacement After A/C System Contamination
NOTE: This refrigerant oil adding method is to be used when a new A/C compressor, suction
accumulator or receiver drier and evaporator core orifice or TXV have been installed due to system
contamination and the A/C system has been flushed.
1. If the new A/C compressor is shipped with a new clutch and pulley already installed, remove the
shipping caps and rotate the new A/C compressor
shaft 6 to 8 revolutions while collecting the oil in a clean measuring cup.
2. Add 60 ml (2 fl oz) directly to the new A/C compressor suction port.
3. Inject the total vehicle PAG oil capacity minus 60 ml (2 fl oz) to the low-side service port during
system charging. For the total PAG oil capacity
specification, refer to the Specifications table.
Oil Injection Using a Dye/Lubricant Injector
NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be
added to the dye/lubricant injector, from the R-134a Loop/Add On Injector Kit-Set, along with the
PAG oil.
1. Evacuate the refrigerant system. For additional information, refer to Air Conditioning (A/C)
System Recovery, Evacuation and Charging See:
Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and Charging.
2. Assemble the dye/lubricant injector and the correct adapters from the R-134a Loop/Add On
Injector Kit-Set to match the amount of refrigerant
compressor oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4335
4. Fill the dye/lubricant injector with the correct amount of clean, new PAG oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the
refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to Air
Conditioning (A/C) System Recovery, Evacuation and
Charging See: Service and Repair/Air Conditioning (A/C) System Recovery, Evacuation and
Charging.
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Diagrams > A/C Compressor Cycling Switch
Information > Diagrams > A/C Compressor Cycling Switch > Page 4341
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component

Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >

Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor /
Switch, HVAC > Component Information > Locations
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Door Position Sensor /
Switch, HVAC > Component Information > Locations > Page 4364

Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Technical Service Bulletins > Customer Interest: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't
Turn OFF/One Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-19-6 > Oct > 09 > A/C - Blower
Motor Won't Turn OFF/One Speed Inop.
Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Component Information > Technical Service Bulletins > All Other Service Bulletins for Blower Motor Switch: > 10-15-1 > Aug
> 10 > Electrical - MIL ON/Multiple DTC's Stored In Memory
Memory
TSB 10-15-1
08/16/10
SERVICE PROCEDURE
303-14.

DEALER CODING
CONDITION
> 10 > Electrical - MIL ON/Multiple DTC's Stored In Memory > Page 4387
BASIC PART NO. CODE
12B637 30
Disclaimer
> 10 > Electrical - MIL ON/Multiple DTC's Stored In Memory > Page 4393
BASIC PART NO. CODE
12B637 30
Disclaimer
Component Information > Technical Service Bulletins > Page 4394
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
Switch, HVAC > Component Information > Diagrams > A/C Compressor Cycling Switch
Switch, HVAC > Component Information > Diagrams > A/C Compressor Cycling Switch > Page 4402
Ford Workshop Manuals > Heating and Air Conditioning > Wiring Harness HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Wiring Harness HVAC: > 10-11-4 > Jun > 10 > A/C - Blower Motor Runs
Wiring Harness HVAC: Customer Interest A/C - Blower Motor Runs Continuously/Compressor
Inop.
TSB 10-11-4
06/21/10

SERVICE PROCEDURE
proceed to Step 3.

(Figure 1)
Cell 5.
(Figure 4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Service Bulletins > Customer Interest for Wiring Harness HVAC: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't Turn
OFF/One Speed Inop.
Wiring Harness HVAC: Customer Interest A/C - Blower Motor Won't Turn OFF/One Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 10-11-4 > Jun > 10 > A/C - Blower Motor
Runs Continuously/Compressor Inop.
Wiring Harness HVAC: All Technical Service Bulletins A/C - Blower Motor Runs
TSB 10-11-4
06/21/10

SERVICE PROCEDURE
proceed to Step 3.

(Figure 1)
Runs Continuously/Compressor Inop. > Page 4426
Cell 5.
(Figure 4)
Runs Continuously/Compressor Inop. > Page 4427
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Service Bulletins > All Technical Service Bulletins for Wiring Harness HVAC: > 09-19-6 > Oct > 09 > A/C - Blower Motor
Won't Turn OFF/One Speed Inop.
Wiring Harness HVAC: All Technical Service Bulletins A/C - Blower Motor Won't Turn OFF/One
Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
Won't Turn OFF/One Speed Inop. > Page 4432
(Figures 2 and 3)
(Figure 4)
Labor Operations)
Won't Turn OFF/One Speed Inop. > Page 4433
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools
are not removed, the supplemental restraint system (SRS) device may not deploy in a crash.
Failure to follow this instruction may result in serious personal injury or death in a crash and
possibly violate vehicle safety standards.
NOTE: After diagnosing or repairing a Supplemental Restraint System (SRS), the restraint system
diagnostic tools (if required) must be removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in
various combinations depending on the impact event.
NOTE: Always refer to the appropriate diagnostic/repair information procedures prior to carrying
out vehicle repairs affecting the SRS and safety belt system.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices are deployed and/or the Restraints Control
Module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the
vehicle SRS is to include the removal of all deployed devices and the installation of new deployable
devices, the removal and installation of new impact sensors, and the removal and installation of a
new RCM. DTCs must be cleared from all required modules after repairs are carried out.
Vehicles with Occupant Classification Sensor (OCS) system
2. NOTE: After installation of new Occupant Classification Sensor (OCS) system components,
carry out the Occupant Classification Sensor (OCS)
System Reset procedure as instructed in the diagnostic/repair information. Refer to the appropriate
diagnostic/repair information for OCS system removal and installation procedure.
When a vehicle has been involved in a collision and the Occupant Classification System Module
(OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following
procedures for the specified system: -
For rail-type OCS system, inspect the passenger side floorpan for damage and repair as
necessary. Install new OCS system rails.
- For weight sensor bolt-type OCS system, inspect the passenger side floorpan for damage and
repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be
cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset.
Do not install a new OCSM unless DTC B1231 cannot be cleared.
- NOTE: Most bladder-type OCSM do not store a DTC B1231 in memory after deployment. The
DTC B1231 is stored only by the RCM.
For bladder-type OCS system, inspect for damage and repair as necessary. If installation of an
OCS system component is required, an OCS system service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles and height
adjusters) must be installed if the vehicle is
involved in a collision that results in deployment of the driver and/or front passenger safety belt
pretensioners. For additional information, refer to Restraint Systems.
6. Inspect the entire vehicle for damage, including the following components:
- Steering column (deployable column if equipped)
- Instrument panel knee bolsters and mounting points
- Instrument panel braces and brackets

Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 4439
- Instrument panel and mounting points
- Seats and seat mounting points
- Safety belts, safety belt buckles and safety belt retractors. For additional information, refer to
Restraint Systems
- SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 4440
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
Safety Belt Procedure After a Collision
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware must
be inspected by an authorized dealer to verify correct function:
- Retractors
- Buckles
- Belt tension sensor (BTS) (if equipped)
- Front safety belt buckle support assemblies (slide bar) (if equipped)
- Safety belt shoulder belt height adjusters (if equipped)
- Child safety seat tether bracket assemblies
- Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the
Functional Tests in the Diagnosis and Testing, a new safety belt assembly must be installed. If any
safety belt assembly attaching areas are damaged or distorted, the sheet metal must be restored to
its original structural integrity and new safety belt assembly and attaching hardware must be
installed. Failure to install new safety belt assemblies and attaching hardware may increase the risk
of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors,
buckles and height adjusters) must be installed. Failure to install new safety belt systems increases
the risk of serious personal injury or death in a crash.
1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected
for damage and distortion. If the attaching points are
damaged and distorted, the sheet metal must be worked back to its original shape and structural
integrity.
2. Install the new safety belt(s). Refer to the procedure. Carry out the Functional Test. For
additional information, refer to the appropriate Functional
Test procedure in Safety Belt System. See: Seat Belt Systems/Testing and Inspection/Component
Tests and General Diagnostics
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering

to Battery.
> Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4446
Deactivation
latches.
impact sensor(s).
to Battery.
See: Air Bag/Service and Repair/Driver Air Bag
Module.
Bag Module See: Air Bag/Service and
Repair/Passenger Air Bag Module. -

connectors.
Reactivation
refer to Battery.
Air Bag/Service and Repair/Driver Air Bag
Module.
Air Bag/Service and Repair/Passenger Air Bag Module.

Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver
Air Bag Module
Air Bag: Locations Driver Air Bag Module
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver
Air Bag Module > Page 4454
Air Bag: Locations Passenger Air Bag Module
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Page
4455
Air Bag: Diagrams
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair
> Driver Air Bag Module
Air Bag: Service and Repair Driver Air Bag Module
Driver Air Bag Module
NOTE: Driver air bag module wire clip (item 5) shown installed on steering wheel for clarity.
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim
cover/tear seam pointed away from the body. Do not set a live air bag module down with the
deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in
serious personal injury in the event of an accidental deployment.
NOTICE: Do not allow driver air bag module to hang from the wiring harness. Damage to the wiring
harness and connectors may occur.
Depowering and Repowering See: Air Bag(s)
Arming and Disarming/Service and Repair/Supplemental Restraint System (SRS) Depowering and
Repowering in the General Procedures.
Steering Column.
3. Rotate the steering wheel to reach the access holes.
- Insert a suitable tool through the access hole, position the tool against the wire clip and push
toward the steering wheel center to disengage
> Driver Air Bag Module > Page 4458
from the attachment hook.
- Slightly pull the driver air bag module away from the steering wheel.
- Repeat this step for the remaining air bag module attachment hooks.
NOTE: Access hole and wire clip locations shown from back of steering wheel.
4. Disconnect the electrical connectors and remove the driver air bag module.
Installation
2. Attach the driver air bag module to the steering wheel.
- Push the driver air bag module firmly to engage the wire clips to the steering wheel attachment
hooks.
3. Install the upper and lower steering column shrouds. For additional information, refer to Steering
Column.
Repowering the General Procedures.
Air Bag: Service and Repair Passenger Air Bag Module
Passenger Air Bag Module
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim
cover/tear seam pointed away from the body. Do not set a live air bag module down with the
deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in
serious personal injury in the event of an accidental deployment.
2. Remove the glove compartment and center instrument panel finish panel. For additional
information, refer to Instrument Cluster / Carrier &/or
3. Through the glove compartment opening:
- Remove the 2 passenger air bag module trim cover screws.
- Remove the 4 passenger air bag module nuts. -
4. Partially remove the passenger air bag module.
- Pull firmly to release the 11 passenger air bag module clips from the instrument panel.
5. Disconnect the electrical connectors and remove the passenger air bag module.
7. Repower the SRS system. For additional information, refer to Supplemental Restraint System
(SRS) Depowering and Repowering See: Air Bag(s)
Air Bag: Service and Repair Side Air Bag Module
Side Air Bag Module
NOTE: Driver seat shown, passenger similar.
Removal
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow
these instructions may result in the seat side air bag module deploying incorrectly and increase the
risk of serious personal injury or death in a crash.
1. Remove the seat. For additional information, refer to Seats.
- Release the side shield rear retainer to access the outboard seat backrest trim cover strap.
3. NOTE: Outboard shown, inboard similar.
Open the backrest cover.
- Release the inboard and outboard vertical J-strips and pin-type retainers.
4. Release the upper rear J-clip from the backrest frame.
5. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or
if the air bag material has been exposed,
install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to
follow these instructions may result in the seat side air bag deploying incorrectly, which increases
WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must
not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and
deployment chute must be installed as a unit. Failure to follow these instructions may result in the
seat side air bag module deploying incorrectly and increase the risk of serious personal injury or
death in a crash.
Remove the side air bag module in the following sequence:
1. Disconnect the side air bag module electrical connector.
2. Remove and discard the 2 nuts and separate the side air bag module from the backrest frame.
3. Remove the side air bag module from the deployment chute.
Installation
WARNING: Before installing the seat side air bag module/deployment chute assembly:
- Inspect the side air bag module and mounting surfaces for any damage or foreign material.
- Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad.
- Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.
WARNING: If the seat side air bag module deployment chute is not correctly positioned, the seat
side air bag may not deploy correctly. Failure to follow this instruction may result in the seat side air
bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
NOTE: If a side air bag deployment took place, a new seat backrest pad, trim cover, side air bag
module and nuts must be installed. A new backrest frame should be installed if necessary.
1. Install the side air bag module in the following sequence:
1. Install the side air bag module into the deployment chute and position the studs through the
holes in the chute and backrest frame.
2. Install the 2 side air bag module nuts.
2. Close the backrest cover in the following sequence.
1. Fasten the upper rear J-clip to the backrest frame.
2. Attach the inboard and outboard pin-type retainers to the backrest frame.
3. Fasten the inboard and outboard vertical J-strips.
3. Fasten all backrest cover strap clips to the springs under the seat.
4. Install the seat. For additional information, refer to Seats.

Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Removal

stops.

Installation
connector.

and Repowering See: Air Bag(s) Arming and Disarming/Service and Repair/Supplemental
Restraint System (SRS) Depowering and Repowering in the General Procedures.
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information
> Diagrams
Air Bag Deactivation Indicator: Diagrams
> Diagrams > Page 4476
> Diagrams > Page 4477
Air Bag Deactivation Indicator: Service and Repair
Passenger Air Bag Deactivation (PAD) Indicator
Turn the key off and wait at least one minute.
2. NOTICE: Use a non-marring tool to pry on the component. Failure to do so will cause damage to
the component.
Pry upward on the upper storage compartment to release the 11 retaining clips.
3. Disengage the locking tabs and remove the PAD indicator.

4. Disconnect the PAD indicator electrical connector.
illuminate continuously for approximately 6 seconds and then turn off. If a SRS fault is present, the
occur until approximately 30 seconds after the ignition has been turned from OFF to the ON
warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5
beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be
diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification
System Module (OCSM).
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information >
Locations
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Clockspring Assembly / Spiral Cable: Diagrams

Clockspring Assembly / Spiral Cable: Service and Repair
Clockspring
Removal
See: Air Bag/Service and Repair/Driver Air Bag
Module.
2. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the
straight-ahead position.
Remove the steering wheel.
4. Remove the 4 screws and clockspring.
Installation
1. NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation key until the
steering wheel is installed. If the
anti-rotation key has been removed before installing the steering wheel, the clockspring must be
centered. Failure to follow this instruction may result in component damage and/or system failure.
Install the clockspring and 4 screws.
3. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in doubt,
repeat the centralizing procedure. Failure
to follow these instructions may increase the risk of serious personal injury or death in a crash.
If a new clockspring was installed and the anti-rotation key has not been removed, proceed to Step
5. If a new clockspring was installed and the anti-rotation key has been removed or the same
clockspring is being installed, rotate the clockspring inner rotor counterclockwise and carefully feel
for the ribbon wire to run out of length with slight resistance. Stop rotating the clockspring inner
rotor at this point.
4. Starting with the clockspring inner rotor, wiring and connector in the 12 o'clock position, rotate
the inner rotor clockwise through 3 revolutions to
center the clockspring. Verify that the clockspring is correctly centered by observing that after 3
revolutions: -
the clockspring rotor window is in the 2 o'clock position and the electrical ribbon is visible in the
window.
- the 2 arrows located on the inner and outer rotor of the clockspring line up in the 7 o'clock
position.
- the clockspring inner rotor, wiring and connector are in the 12 o'clock position.
5. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the
straight-ahead position.
NOTE: The clockspring inner rotor, wiring and connector must be in the 12 o'clock position to install
the steering wheel.
If a new clockspring was installed, remove the anti-rotation key. Install the steering wheel. For
additional information, refer to Steering Column.
Air Bag/Service and Repair/Driver Air Bag
Module.
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Front Impact Sensor, Left
Front Impact Sensor, Left > Page 4490
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams >
Front Impact Sensor, Left




Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front Impact Severity Sensor
Repair > Front Impact Severity Sensor > Page 4500
Repowering.
Repair > Front Impact Severity Sensor > Page 4501
Side Impact Sensor
- Remove the nut. -
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag >

Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information >
Locations

Removal
portion of Seats.
bracket.
spring.
Installation
engaged. -
portion of Seats.
death in a crash.
less than 18 volts.
Motor Company. -
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information >
Locations


Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Removal
Depowering and Repowering See: Air Bag
Systems/Air Bag(s) Arming and Disarming/Service and Repair/Supplemental Restraint System

(SRS) Depowering and Repowering in the General Procedures.

stops.

Installation
connector.

and Repowering See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and
Repair/Supplemental Restraint System (SRS) Depowering and Repowering in the General
Procedures.
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Locations > Page 4535

Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering

to Battery.
Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and Repowering > Page 4541
Deactivation
latches.
impact sensor(s).
to Battery.
See: Air Bag Systems/Air Bag/Service and
Repair/Driver Air Bag Module.
Bag Module See: Air Bag Systems/Air
Bag/Service and Repair/Passenger Air Bag Module. -

connectors.
Reactivation
refer to Battery.
Air Bag Systems/Air Bag/Service and
Repair/Driver Air Bag Module.
Air Bag Systems/Air Bag/Service and Repair/Passenger Air Bag Module.

Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Child Seat Tether Attachment: Service and Repair
Child Safety Seat Tether Anchor
- Retractors
- Buckles

WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure to follow
this instruction may result in the child's safety seat being incorrectly secured, which increases the
risk of serious personal injury or death to the child in a sudden stop or crash.
1. Push the 2 buttons on the head restraints guide sleeves and remove the head restraints.
2. Place the rear seat in the cargo position.
3. Remove the bolt and child safety seat tether anchor.

Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Safety Belt Buckle - Front
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Front
Safety Belt Buckle - Front
- Retractors
- Buckles
and Repair > Safety Belt Buckle - Front > Page 4553
(RCM) fuse is removed and the ignition in ON.
Depowering and Repowering in the General
Procedures portion of Restraint Systems.
2. Loosen the bolt and disconnect the seat electrical bulkhead connector.
3. Lift and position aside the selector lever trim panel.
4. Remove the covers and 4 screws from the floor console rear section.
5. Remove the floor console rear section in the following sequence:
1. If equipped, remove the window control switch.
2. Guide the park brake lever boot over the park brake handle.
6. Remove the bolt and safety belt buckle.
Insert a suitable tool to release the locking tab and remove the brown safety belt buckle electrical
connector from the seat electrical bulkhead connector. Separate the wire harness from under the
seat.
9. Repower the SRS. For additional information refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General
Procedures portion of Restraint Systems.
10. Check the active restraint system for correct operation. For additional information, refer to
Safety Belt System. See: Testing and
Inspection/Component Tests and General Diagnostics

Seat Belt Buckle: Service and Repair Safety Belt Buckle - Rear, Center and RH
Safety Belt Buckle - Rear, Center and RH
NOTE: The upper graphic shows center safety belt buckle, lower graphic shows RH safety belt
buckle.
- Retractors
- Buckles
1. Position the rear seat(s) in the cargo position.
2. Remove the bolt(s) and safety belt buckle(s).
3. To install reverse the removal procedure.
4. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test procedure in Safety
Belt System. See: Testing and Inspection/Component Tests and General Diagnostics
Seat Belt Buckle: Service and Repair Safety Belt Buckle - Rear, LH
Safety Belt Buckle - Rear, LH
1. Push the 2 buttons on the head restraint guide sleeves and remove the head restraints.
2. Place the seat in the cargo position.
3. NOTE: Note the spacer shoulder position and safety belt routing for correct installation.
Remove the bolt, safety belt buckle, center safety belt anchor, washer spacer and cover.

- Before installation, make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupants.
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair
Seat Belt Height Adjuster: Service and Repair
Safety Belt Shoulder Height Adjuster
- Retractors
- Buckles

2. Remove bolts and safety belt shoulder height adjuster
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Service and Repair
Seat Belt Reminder Lamp: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated through the driver
safety belt buckle.
NOTE: The Belt-Minder(R) can also be deactivated/activated using the scan tool.
1. Place the transmission selector lever in PARK.
3. Unbuckle the driver and front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the RUN position (do not start the engine).
2. Wait approximately 1 minute until the safety belt warning indicator turns off.
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
NOTE: Buckle and unbuckle the safety belt at a moderate rate. If the safety belt
buckle/unbuckle/buckle sequence is carried out too fast, the Restraints Control Module (RCM) can
fail to recognize one of the sequences and the procedure must be repeated.
To disable or enable the Belt-Minder(R) feature, buckle then unbuckle the driver safety belt 9 times,
ending in the unbuckled state.
- This disables the Belt-Minder(R) feature for both driver and passenger seating positions, if it is
currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for
3 seconds.
- This enables the Belt-Minder(R) feature for both driver and passenger seating positions, if it is
currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for
3 seconds, followed by 3 seconds with the light off, then followed by the safety belt warning
indicator flashing 4 times per second for 3 seconds again.
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > Safety Belt Retractor and Pretensioner
Seat Belt Retractor: Service and Repair Safety Belt Retractor and Pretensioner
Safety Belt Retractor and Pretensioner
- Retractors
- Buckles
buckles and height adjusters) must be installed. Failure to install new safety belt
Service and Repair > Safety Belt Retractor and Pretensioner > Page 4567
systems increases the risk of serious personal injury or death in a crash.
1. Depower the SRS. For additional information, refer to the General Procedures portion of
Restraint Systems.
2. Remove the safety belt retractor anchor bolt.
4. For RH, disconnect the Belt Tension Sensor (BTS) electrical connector.
5. NOTICE: Route the Belt Tension Sensor (BTS) wiring under the carpet strap to prevent damage
from the seat track.
Remove the BTS wiring from under the carpet strap.
6. Remove the bolt and safety belt retractor.
7. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts
and buckles are accessible to the occupants.
8. Repower the SRS. For additional information, refer to the General Procedures portion of
Restraint Systems.
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear, Center
Safety Belt Retractor - Rear, Center
- Retractors
- Buckles
safety belt assembly attaching areas are damaged or distorted, the sheet metal must be
restored to its original structural integrity and new safety belt assembly and attaching hardware
must be installed. Failure to install new safety belt assemblies and attaching hardware may
increase the risk of serious personal injury or death in a crash.
1. Push the 2 buttons on the head restraint guide sleeves and remove the head restraints.
2. Place the seat in the cargo position.
3. Remove the screw and safety belt cover.
4. Remove the bolt and safety belt anchor.
5. Open the backrest cover J-clips.
6. Unzip the inboard backrest trim cover.
7. Position the backrest reinforcement pad aside and remove the bolt and rear center safety belt
retractor.
Seat Belt Retractor: Service and Repair Safety Belt Retractor - Rear, Outboard
Safety Belt Retractor - Rear, Outboard
- Retractors
- Buckles
1. Remove the D-ring cover and bolt.
2. Remove the safety belt retractor anchor bolt.
3. Remove the bolt and safety belt retractor.

Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information >
Diagrams > Safety Belt Buckle Pretensioner, Passenger
Seat Belt Tensioner: Diagrams Safety Belt Buckle Pretensioner, Passenger

Diagrams > Safety Belt Buckle Pretensioner, Passenger > Page 4576
Seat Belt Tensioner: Diagrams Safety Belt Retractor Pretensioner, Driver

Seat Belt Tensioner: Diagrams Safety Belt Tensioner, Passenger Seat
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch >
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Front Impact Sensor, Left
Information > Locations > Front Impact Sensor, Left > Page 4587
Information > Diagrams > Front Impact Sensor, Left

Information > Diagrams > Front Impact Sensor, Left > Page 4592



Information > Service and Repair > Front Impact Severity Sensor


Information > Service and Repair > Front Impact Severity Sensor > Page 4597

(SRS) Depowering and Repowering.
Side Impact Sensor

- Remove the nut. -

(SRS) Depowering and Repowering in the General
Procedures.
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor >

Removal
portion of Seats.
bracket.
spring.
Installation
engaged. -
portion of Seats.
death in a crash.
less than 18 volts.
Motor Company. -
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor >


Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Antenna Cable: Service and Repair
Antenna Cable - AM/FM
1. Remove the Audio Control Module (ACM). For additional information, refer to Audio Control
Module (ACM) See: Cellular
Phone/Communications Control Module/Service and Repair/Removal and Replacement/Audio

Control Module (ACM).
2. Remove the front headliner.
3. Loosen the bolt completely and disconnect the AM/FM antenna cable from the AM/FM antenna.
4. Remove the AM/FM antenna cable.

Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transmitter
> Component Information > Service and Repair
Alarm System Transmitter: Service and Repair
Passive Anti-Theft System (PATS) Transceiver
1. If equipped, using a suitable tool (such as a pocket screwdriver), insert it into the access hole,
release the audio controls stalk and position it aside.
- Slide the audio controls stalk to the left to release it from the steering column.
2. Release the steering column lever and move the steering column to the full outward and upward
position.
3. Remove the 2 screws and the lower steering column shroud.
4. Disconnect the Passive Anti-Theft System (PATS) transceiver electrical connector.
5. Using a suitable tool (such as a dentist pick), release the tabs and remove the PATS transceiver.
6. NOTE: Replacement of the PATS transceiver does not require the PATS keys to be
programmed into the Instrument Cluster (IC) again.

Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Locations
Alarm System Transponder: Locations
Transponder > Component Information > Locations > Page 4629
Alarm System Transponder: Diagrams
Transponder > Component Information > Locations > Page 4630
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Transmitter > Component Information > Testing and Inspection > Remote Keyless Entry (RKE) Transmitter
Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter
Programming
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: A maximum of 4 Remote Keyless Entry (RKE) transmitters can be programmed to the
vehicle. Programming must be done at the same time for all the RKE transmitters.
1. NOTE: Make sure the front doors are unlocked and closed, and the ignition is in the OFF
position.
Turn the ignition switch from the OFF to the RUN position 4 times in rapid succession (within 6
seconds), with the fourth turn ending in OFF. If the Generic Electronic Module (GEM) successfully
enters program mode, the Instrument Cluster (IC) sounds a chime.
2. NOTE: If no action is taken within 10 seconds after a transmitter has been programmed, the
programming sequence ends.
Within 10 seconds, press any button on the RKE transmitter to be programmed. The IC chimes to
confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter.
3. NOTE: There are NO chimes or any other confirmation from the IC upon exiting programming
mode.
Exiting the programming mode is accomplished if one of the following occurs: -
The ignition transitions to the RUN position.
- 10 seconds have passed since entering programming mode or since the last RKE transmitter was
programmed.
- The maximum number (4) of RKE transmitters have been programmed.
4. Check the operation of the transmitter. If the door locks do not respond for the programmed RKE
transmitter(s), wait several seconds and press the
button again. If the door locks still fail to respond, refer to Handles, Locks, Latches and Entry
Systems. (Make sure that no more than the maximum number of RKE transmitters are attempted
to be programmed.) See: Body and Frame/Locks/Power Locks/Testing and Inspection
Programming > Page 4636
Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming
Autolock and Auto-Unlock Programming
Programming the Autolock Feature
NOTE: This vehicle is not equipped with an Auto-Unlock feature.
NOTE: Make sure that the key is in the OFF position and the doors are closed and unlocked.
NOTE: When programming the autolock feature using the door lock lever method, the following
steps must be carried out within 30 seconds or the procedure will need to be repeated. If the
procedure needs to be repeated, wait 30 seconds between programming sessions.
1. NOTE: If the driver seat belt is not buckled, the Instrument Cluster (IC) will sound the seat belt
warning chime instead of the autolock
programming mode confirmation chime.
Buckle the driver seat belt.
2. Turn the ignition key from the OFF to the RUN position.
3. Push (lock) and pull (unlock) the driver door lock lever 3 times.
4. Turn the ignition key from the RUN to the OFF position.
6. Turn the ignition key to the RUN position. The IC sounds a chime to indicate that programming
mode is entered.
7. To enable/disable the autolock feature, push (lock) and pull (unlock) the driver door lock lever
one time to toggle the state of the autolock feature.
The IC sounds 2 chimes if the autolock has been enabled and 1 chime if the autolock has been
disabled.
8. Turn the ignition key to the OFF position.

Programming > Page 4637
Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming
Stepped Unlock Programming
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the
Remote Keyless Entry (RKE) transmitter
simultaneously for 4 seconds. -
The turn signals flash twice to indicate the mode change.
2. Repeat Step 1 to enable/disable the stepped unlocking feature.

Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone >
Cellular Phone Microphone: Diagrams

Ford Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module >
Component Information > Locations > Audio Control Module (ACM)
Component Information > Locations > Audio Control Module (ACM) > Page 4646
Component Information > Locations > Audio Control Module (ACM) > Page 4647
Component Information > Diagrams > Audio Control Module (ACM)

Component Information > Diagrams > Audio Control Module (ACM) > Page 4650



screen goes blank.

screen goes blank.
selection.
website

selection.

Removal
connectors.
Installation

In-Dash Computer
In-Dash Computer
In-Dash Computer

Telematics Module
Telematics Module
Removal

Installation
3. Wait 10 seconds.
In-Dash Computer.
ground eyelet.
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations
Parking Assist Control Module > Component Information > Locations > Page 4672

Parking Assist Control Module > Component Information > Locations > Page 4673


Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left > Page 4678
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left > Page 4683
Parking Assist Distance Sensor > Component Information > Diagrams > Page 4690
Parking Aid Sensor
Removal
sensor does not respond correctly, refer to Parking Aid in the Diagnosis and Testing See: Testing
and Inspection.
Parking Assist Warning Indicator > Component Information > Diagrams
Parking Assist Warning Indicator: Diagrams

Ford Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack,
Entertainment System > Component Information > Diagrams
Auxiliary Input / Output Jack: Diagrams
Entertainment System > Component Information > Diagrams > Page 4698
Entertainment System > Component Information > Diagrams > Page 4699
Auxiliary Input / Output Jack: Service and Repair
Audio Input Jack
1. Using a suitable tool (such as a trim removal tool), remove the floor console front trim by
releasing the clips.
2. Remove the audio input jack.
1. Slide the retainer backward.
2. Pull the audio input jack from the floor console front trim.

Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Locations
Remote Control: Locations
Audio - Stereo > Component Information > Locations > Page 4704
Remote Control: Diagrams
Remote Control: Service and Repair

Steering Wheel Controls
1. Using a suitable tool (such as a 90-degree pick), release the tab at the back of the steering
wheel controls by pressing it straight in.
2. Remove the steering wheel controls by pulling them straight out of the steering column.

Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Speaker, Left Front
Speaker: Diagrams Speaker, Left Front
Component Information > Diagrams > Speaker, Left Front > Page 4711
Speaker: Diagrams Speaker, Right Front
Speaker: Service and Repair
Speaker - Door
NOTE: LF door shown, RF door similar.
1. Remove the front door trim panel.
2. Remove the 4 screws and the door speaker.

Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Communications Control Module > Component Information > Locations > Audio Control Module (ACM)
Equipment > Communications Control Module > Component Information > Locations > Audio Control Module (ACM) > Page
4720
Equipment > Communications Control Module > Component Information > Locations > Audio Control Module (ACM) > Page
4721
Equipment > Communications Control Module > Component Information > Diagrams > Audio Control Module (ACM)

Equipment > Communications Control Module > Component Information > Diagrams > Audio Control Module (ACM) > Page
4724
4725
4726

4727
4728
4729

4730
4731
4732
4733

Equipment > Communications Control Module > Component Information > Service and Repair > Procedures
screen goes blank.

Equipment > Communications Control Module > Component Information > Service and Repair > Procedures > Page 4736
screen goes blank.
selection.
website

selection.

Removal
connectors.
Installation

In-Dash Computer
In-Dash Computer
In-Dash Computer

Telematics Module
Telematics Module
Removal

Installation
3. Wait 10 seconds.
In-Dash Computer.
ground eyelet.
Equipment > Parking Assist Control Module > Component Information > Locations
Equipment > Parking Assist Control Module > Component Information > Locations > Page 4745

Equipment > Parking Assist Control Module > Component Information > Locations > Page 4746


Equipment > Voice Activation Module > Component Information > Locations
Equipment > Voice Activation Module > Component Information > Locations > Page 4750
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left
Equipment > Parking Assist Distance Sensor > Component Information > Locations > Parking Aid Sensor, Outer Left >
Page 4758
Page 4759
Page 4760
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Parking Aid Sensor, Outer Left >
Page 4763
Page 4764
Page 4765
Page 4766
Page 4767
Page 4768
Page 4769
Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 4770
Parking Aid Sensor
Removal
sensor does not respond correctly, refer to Parking Aid in the Diagnosis and Testing See: Collision
Avoidance and Parking Assist Systems/Testing and Inspection.
Ford Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Microphone
> Component Information > Diagrams
Voice Activation Microphone: Diagrams

Ford Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Microphone
> Component Information > Diagrams > Page 4775
Voice Activation Microphone: Service and Repair
Microphone
1. Remove the LH A-pillar trim panel.
2. Remove the microphone.

Ford Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module >
Ford Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations

Removal
mode DTC is:
mechanisms.
Installation

Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Front Bumper Cover / Fascia: Service and Repair
Bumper Cover - Front

1. Remove the fender splash shields.
2. Remove the 5 radiator sight shield screws.
3. Remove the 4 front bumper cover side bolts (2 each side).
4. Remove the fender mouldings. For additional information, refer to Auxiliary Step / Running
Board.
5. If equipped, disconnect the fog lamp electrical connector.
6. Disconnect the side marker lamp electrical connector.
7. Remove the 2 front bumper cover front bolt covers.
8. Remove the 2 front bumper cover-to-bumper front bolts.
9. Remove the front bumper cover.

Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair
Rear Bumper Cover / Fascia: Service and Repair
Bumper Cover - Rear
Side covers
1. Remove the rear bumper side cover star washer.
2. Pull outward on the rear bumper side covers to release the pin-type retainer from the body.
3. Remove the rear bumper side cover.

Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Page 4803
- Pull inward to release the rear bumper side cover clips from the bumper.
Upper bumper cover
4. Pull upward to release the rear bumper upper cover clips from the bumper.
5. Remove the rear bumper upper cover.
- Pull outward to release it from the bumper.
All vehicles

Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Technical Service
Bulletins > Customer Interest for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
Cowl Moulding / Trim: Customer Interest Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
This article supersedes TSB 10-4-9 to update the model years and Service Procedure.
ISSUE Some 2010-2011 Transit Connect vehicles may exhibit water leaks in various areas of the
vehicle.
SERVICE PROCEDURE
Water Leak From Center High Mounted Stop Lamp - Built On Or Before 9/27/2009
1. Remove the interior courtesy lamp cover. (Figure 1)

Bulletins > Customer Interest for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues > Page
4813
2. Check for trapped lamp wiring or partial installation of the grommet. (Figures 2-3)
3. If wiring is trapped or grommet is not fully installed.
a. Adjust wiring and grommet as necessary. (Figure 4)
b. Perform a leak test.
c. No leaks, return vehicle to customer.
d. If leak persists, go to Step 4.
4. If wiring or grommet positioning are fine and water leak is still present, remove the rear headliner
to remove the high mounted stop lamp.
4814
5. Use an alcohol wipe to clean the area around the wiring hole. Apply Motorcraft® Seam Sealer.
(Figure 5)
6. Install the high mounted lamp, torque the nuts 22 lb-in (2.5 N.m), attach the wiring connectors.
7. Check the operation of the lamp.
8. Install the rear head liner.
Water Leak From Rear Cargo Doors (Figure 6)
1. If leakage is observed to be around the door striker area, vehicles built on or before 6/28/2010,
adjust the strikers so that they move towards the front
of the vehicle ensuring that door seals fully to the seals on the body. (Figure 6 Area A)
2. If leakage is observed to be around the door flush-gap area. (Figure 6 Area B and/or C)
4815
a. Check for cracks/holes in the body sealer that is applied between the body panels. Repair the
cracks as necessary using Motorcraft® Seam Sealer.
(Figure 7)
b. If the water travels under the body weather strip, as shown in Figure 7, remove the weather strip,
check the body panel flanges for waviness or
irregularities. Repair the flanges as necessary. Apply Motorcraft® Seam Sealer through the
channel of the weather strip for better adhesion and reinstall the weather strip.
3. If water leakage is observed only from area C of Figure 6, remove the body weather strip from
lower bottom corners. Apply Motorcraft(R) Seam
Sealer through the channel of the weather strip, around the lower bottom corners.
Water Leak Into The Footwell Or Heater Blower Case
1. Check for water leaking into the foot well area:
a. If there is evidence of water leaking through dash panel on vehicles built on or before 10/4/2010,
the front floor A-pillar opening needs to be
sealed. Follow Sealing A-pillar Opening.
b. If there is evidence of water leaking through the floor vents and blower motor case, then the
pollen filter case base needs to be sealed, follow
Sealing Pollen Filter Case Base.
Sealing A-pillar Opening
1. Check for water leaking into the footwell through the dash panel. If there is evidence of water
leaking through the front floor on the driver or
passenger side the A-pillar opening needs to be sealed.
2. Remove the upper cowl grill panel and its support on the passenger or driver side where the leak
occurred. Refer to Workshop Manual (WSM),
Section 501-2 Front End Body Panels.
3. Apply flexible foam inside the bracket mounting area and the windshield, just next to the hood
hinge.
4. Apply Motorcraft® Seam Sealer over the foam applied area encircled. (Figure 8)
5. Install the cowl grill panel and support.

4816
6. Dry the carpet and other interior trim as necessary.
Sealing Pollen Filter Case Base
1. Check for water leaking into the foot well through the floor vents. If there is evidence of water
leaking through the floor vents and blower motor case,
then the pollen filter case base gasket needs to be sealed.
2. Remove upper and lower cowl grill panels, to gain access to the pollen filter. Refer to WSM,
3. Remove pollen filter case.
4. Apply Motorcraft(R) Seam Sealer on case gasket. (Figure 9)
5. Install pollen filter case and cowl grills. Ensure that the lower cowl grill fully seats on the seal,
under the hood.
6. Dry the carpet and other interior trim as necessary
Inspect For Trapped Lamp Wiring Or Partial Installed Grommet And Repair As Necessary, And
Perform Leak Test Can Be Claimed
4817
With Operations C, D, E And F (Do Not Use With Any Operations Outside Of This Article)
Perform Leak Test. Reseal The High Mounted Stop Lamp Can Be Claimed With Operations C, D,
E And F (Do Not Use With Any Operations Outside Of This Article)
110310C 2010 Transit Connect: 0.2 Hr.
Adjust Rear Cargo Door Stryker Can Be Claimed With A, Or B, D, And E Or F (Do Not Use With
Any Operations Outside Of This Article)
110310D 2010 Transit Connect: 0.4 Hr.
Apply Seam Sealer Onto The Channel Where Necessary Can Be Claimed With A Or B, C And E
Or F (Do Not Use With Any Operations Outside Of This Article)
110310E 2010 Transit Connect: 0.6 Hr.
Apply Sealer, Includes Time To Remove and Install Cowl Grill, Bracket, And Remove And Install
Carpet To Dry Can Be Claimed With A Or B, C, And D (Do Not Use With Any Operations Outside
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
Connect: Seal The Pollen Filter Case, Apply Sealer Between The Bracket And Windshield Includes
Time To Remove and Install Cowl Grill, Bracket, And
Remove And Install Carpet To Dry Can Be Claimed With A, Or B, C And D (Do Not Use With Any
Operations Outside Of This Article)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
4818
Disclaimer
Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water Leak
Issues
Cowl Moulding / Trim: All Technical Service Bulletins Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Issues > Page 4824
Issues > Page 4825
(Figure 5)
Issues > Page 4826
(Figure 7)
hinge.

Issues > Page 4827
under the hood.
Issues > Page 4828
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Issues > Page 4829
Disclaimer
Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 4830
Cowl Moulding / Trim: By Symptom
Technical Service Bulletin # 11-3-10 Date: 110315
Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Cowl Moulding / Trim: Service and Repair
Cowl Panel Grille
Upper cowl panel grille
1. Remove the windshield wiper arms. For additional information, refer to Wiper and Washer
Systems.
2. Remove the 3 upper RH cowl panel grille screws.
3. Remove the 2 upper RH cowl panel grille pin-type retainers.
4. Remove the RH outer upper cowl panel screw.
5. Remove the upper RH cowl panel grille.
6. Remove the 3 upper LH cowl panel grille screws.

7. Remove the 3 upper LH cowl panel grille pin-type retainer.
8. Remove the outer upper cowl panel screw.
9. Remove the upper LH cowl panel grille.

Lower cowl panel grille
10. Remove the master cylinder reservoir mounting bolts and reposition the master cylinder.
11. Remove the purge valve bracket bolts and reposition the purge valve bracket assembly.
12. Loosen the Battery Junction Box (BJB) mounting bolt and reposition the BJB.
13. Remove the 3 lower cowl panel screws.
14. Remove the upper cowl panel grille support.
15. Remove the 2 lower cowl panel pin-type retainers.
16. Remove the 4 lower cowl panel bolts.
17. Remove the lower cowl panel.
All vehicles

Ford Workshop Manuals > Body and Frame > Cowl > Cowl Weatherstrip > System Information > Technical Service
Bulletins > Customer Interest for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
Cowl Weatherstrip: Customer Interest Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Bulletins > Customer Interest for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues > Page
4853
4854
(Figure 5)
4855
(Figure 7)
hinge.

4856
under the hood.
4857
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
4858
Disclaimer
Bulletins > All Technical Service Bulletins for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
Cowl Weatherstrip: All Technical Service Bulletins Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

> Page 4864
> Page 4865
(Figure 5)
> Page 4866
(Figure 7)
hinge.

> Page 4867
under the hood.
> Page 4868
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
> Page 4869
Disclaimer
Bulletins > All Technical Service Bulletins for Cowl Weatherstrip: > Page 4870
Cowl Weatherstrip: By Symptom
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair > Door Handle Reinforcement - Exterior, Front
Front Door Exterior Handle: Service and Repair Door Handle Reinforcement - Exterior, Front
Door Handle Reinforcement - Exterior, Front
1. Remove the exterior front door handle. For additional information, refer to Exterior Front Door
Handle See: Exterior Front Door Handle.
2. Remove the exterior front door handle seals.
3. Remove the exterior front door handle reinforcement nut.
4. Push the exterior front door handle reinforcement into the door and remove.

- After installation, carry out the door handle to latch rod adjustment. For additional information,
refer to Door Handle to Latch Rod Adjustment See: Front Door Latch/Adjustments.
Door Exterior Handle > System Information > Service and Repair > Door Handle Reinforcement - Exterior, Front > Page
4891
Front Door Exterior Handle: Service and Repair Exterior Front Door Handle
Exterior Front Door Handle
Removal
1. Remove the front door latch. For additional information, refer to Front Door Latch See: Front
Door Latch/Service and Repair/Removal and
Replacement/Front Door Latch.
2. Remove the exterior front door handle bezel screw.
3. Remove the exterior front door handle bezel.
4. Remove the exterior front door handle.
1. Slide the exterior front door handle toward the rear of the vehicle to disengage it from the
exterior front door handle reinforcement.
2. Pull outward on the exterior front door handle.

4892
Installation
1. Install the exterior front door handle.
1. From the inside of the door, push the exterior door handle actuating lever.
2. Slide the exterior front door handle across the exterior door handle actuating lever.
2. Install the exterior front door handle bezel.
3. Install the exterior front door handle bezel screw.
4. Install the front door latch. For additional information, refer to Front Door Latch See: Front Door
Latch/Service and Repair/Removal and
Replacement/Front Door Latch. -

After installation, carry out the door handle to latch rod adjustment. For additional information, refer
to Door Handle to Latch Rod Adjustment See: Front Door Latch/Adjustments.
4893
Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches -
Exploded View
Front Door Handles, Locks and Latches - Exploded View
Door Interior Handle > System Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View
Front Door Interior Handle: Service and Repair Front Door Handles, Locks and Latches - Exploded
View

Door Interior Handle > System Information > Service and Repair > Front Door Handles, Locks and Latches - Exploded View
> Page 4898
Front Door Interior Handle: Service and Repair Interior Door Handle - Front
Interior Door Handle - Front
2. Remove the front door interior door handle cable from the handle.
- Place the interior door lock lever into the lock position.
- Remove the door handle cable from the handle.
3. Remove the interior front door handle.
1. Pull the front of the interior door handle away from the inner door panel.
2. Unhook the interior door handle from the inner door panel.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System
Front Door Hinge: Adjustments
Door Alignment - Front
All alignments
1. Remove the door latch striker plate.
Front door in and out, up and down alignment
2. Loosen, but do not remove, the front door hinge-to-door bolts enough to allow for door
alignment.
Front door fore, aft and tilt alignment
3. Loosen, but do not remove, the front door hinge-to-body fasteners enough to allow door
alignment.
All alignments
4. Adjust the door. For additional information on dimensions, refer to Body and Frame /
Specifications / Dimensions.
5. Tighten the door fasteners.
- Tighten the front door hinge-to-door bolts to 28 Nm (21 lb-ft).
- Tighten the front door hinge-to-body fasteners to 25 Nm (18 lb-ft).
6. Install and adjust the door striker as necessary. For additional information, refer to Striker
Adjustment See: Adjustments/Striker Adjustment.
7. For additional information on body margins, refer to Body and Frame / Specifications / Panel
Gap Tolerances..
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Front Door Latch: Adjustments
Door Handle to Latch Rod Adjustment
NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door
hard to open from the outside door handle, or the outside door handle to not sit flush in the closed
position.
NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and
linkages must be installed on the door.
1. Raise the door glass to the full-up position.
2. Remove the door trim panel.
3. Position the water shield aside.
4. Open the clip and disconnect the exterior door handle actuating rod.
5. Position the actuating rod and latch actuating lever in a neutral position.
6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever.
Reinstall the exterior door handle actuating rod back into the clip.
7. Close the clip and test the system to make sure that the exterior door handle is operating
correctly.
8. Reseal the water shield.
9. Install the door trim panel.

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

1. Remove the front door lock cylinder. For additional information, refer to Door Lock Cylinder -
Front See: Locks/Door Locks/Door Lock
Cylinder/Service and Repair/Removal and Replacement/Door Lock Cylinder - Front.
2. Remove the interior front door handle. For additional information, refer to Interior Door Handle -
Front See: Front Door Handle/Front Door
Interior Handle/Service and Repair/Interior Door Handle - Front.
3. Disconnect the front door latch electrical connector.
4. Open the clip and disconnect the exterior front door handle actuating rod.
5. Remove the 3 front door latch bolts.
6. Remove the front door latch from the front door.
refer to Door Handle to Latch Rod Adjustment See: Adjustments.
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System
Front Door Limiter: Service and Repair
Door Check Arm
2. Remove the door check arm-to-body bolt.
3. Remove the door check arm-to-door nuts.
4. Remove the door check arm.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Front Door Panel: Service and Repair
Door Trim Panel - Front
1. Remove the front door trim panel pull handle.
- Remove the pull handle cover.
- Remove the pull handle screws. -
2. Remove the front door inside handle bezel screw and bezel.
3. If equipped with manual windows, remove the manual window handle retaining clip and the
handle.
4. Remove the 9 front door trim panel screws.
- If equipped, disconnect the power mirror switch electrical connector.
- Pull the bottom of the front door trim panel outward.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
- Lift the front door trim panel upward.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip >
Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 11-2-18 > Feb >
11 > Body - Front Door Upper Weatherstrip Loose/Falling Off
Front Door Weatherstrip: Customer Interest Body - Front Door Upper Weatherstrip Loose/Falling
Off
TSB 11-2-18
02/28/11
SERVICE PROCEDURE

NOTE
°F) CONTINUOUSLY.
complete adhesion

Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 11-2-18 > Feb >
11 > Body - Front Door Upper Weatherstrip Loose/Falling Off > Page 4924
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
110218B 2010-2011 Transit 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: >
11-2-18 > Feb > 11 > Body - Front Door Upper Weatherstrip Loose/Falling Off
Loose/Falling Off
TSB 11-2-18
02/28/11
SERVICE PROCEDURE

NOTE
°F) CONTINUOUSLY.
complete adhesion

Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: >
11-2-18 > Feb > 11 > Body - Front Door Upper Weatherstrip Loose/Falling Off > Page 4930
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
110218B 2010-2011 Transit 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms -
Exploded View, Front Door
Front Door Window Glass Weatherstrip: Service and Repair Glass, Frames and Mechanisms -
Glass, Frames and Mechanisms - Exploded View, Front Door

Exploded View, Front Door > Page 4936
Front Door Window Glass Weatherstrip: Service and Repair Door Glass Top Run - Front
Door Glass Top Run - Front
1. Lower the front door glass to the fully DOWN position.
2. Remove the exterior mirror assembly. For additional information, refer to Mirrors.
3. Remove the exterior door window weatherstrip.
- Begin pulling up at rear edge of weatherstrip, and work along the remaining weatherstrip pulling
straight up.
4. Remove the interior door trim panel.
5. Remove the interior door window weatherstrip.
6. Remove the watershield.
7. Remove the insulation pads.
8. Remove the quarter window glass division bar lower retaining screw.

Exploded View, Front Door > Page 4937
9. Remove the access plug and the quarter window glass division bar upper retaining screw.
10. Position aside the top run weatherstrip channel.
11. Remove the top run and front door quarter glass assembly from the door opening.
1. Tip the top run and front door quarter glass rearward.
2. Slide the top run and front door quarter glass assembly upward.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Front Door

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 4942
Front Door Window Motor: Service and Repair Window Regulator and Motor - Front Door
Window Regulator and Motor - Front Door
3. Remove the 2 door window glass clamp bolts.
4. Secure the front window glass in the full UP position with tape.
5. Remove the 4 window regulator nuts and 3 regulator bolts.
6. Disconnect the window regulator motor electrical connector.
7. Remove the window regulator and motor assembly.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Front Door

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door >
Page 4947
Front Door Window Regulator: Service and Repair Window Regulator and Motor - Front Door

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair > Door Handle Reinforcement - Exterior, Rear
Rear Door Exterior Handle: Service and Repair Door Handle Reinforcement - Exterior, Rear
Door Handle Reinforcement - Exterior, Rear
1. Remove the right hand center door latch. For additional information, refer to Rear Door Latch -
Center, RH See: Rear Door Latch/Service and
Repair/Removal and Replacement/Rear Door Latch - Center, RH.
2. Remove the exterior rear door handle. For additional information, refer to Exterior Rear Door
Handle See: Exterior Rear Door Handle.
3. Remove the exterior rear door handle seals.
4. Remove the exterior rear door handle reinforcement nut.

5. Push the exterior rear door handle reinforcement into the door and remove.
refer to Door Handle to Latch Rod Adjustment See: Front Door/Front Door Latch/Adjustments.
Door Exterior Handle > System Information > Service and Repair > Door Handle Reinforcement - Exterior, Rear > Page
4954
Rear Door Exterior Handle: Service and Repair Exterior Rear Door Handle
Exterior Rear Door Handle
Removal
1. Remove the exterior rear door handle bezel screw access plug from the inside of the rear door.
2. Remove the exterior rear door handle bezel screw.
3. Remove the exterior rear door handle bezel.
4. Remove the exterior rear door handle.
1. Slide the exterior rear door handle toward the left side of the vehicle to disengage it from the
exterior rear door handle reinforcement.
2. Pull outward on the exterior rear door handle.
Installation
1. Install the exterior rear door handle.
4955
2. Slide the exterior rear door handle across the exterior door handle actuating lever.
2. Install the exterior rear door handle bezel.
3. Install the exterior rear door handle bezel screw.
4. Install the exterior rear door handle bezel screw access plug.
4956
Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded
View
Rear Door Handles, Locks and Latches - Exploded View
Left Rear Door
Right Rear Door

4957
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System
Rear Door Hinge: Adjustments
Door Alignment - Rear
All alignments
1. Remove the door latch striker plate.
Rear door in and out, up and down alignment
2. Loosen, but do not remove, the rear cargo door hinge-to-door bolts enough to allow door
alignment.
Front door fore, aft and tilt alignment
3. Loosen, but do not remove, the rear cargo door hinge-to-body bolts enough to allow door
alignment.
All alignments
4. Adjust the door.
5. Tighten the door fasteners.
- Tighten the rear cargo door hinge-to-door bolts to 25 Nm (18 lb-ft).
- Tighten the rear cargo door hinge-to-body bolts 25 Nm (18 lb-ft).
6. Install and adjust the door striker as necessary. For additional information, refer to Striker
Adjustment See: Front Door/Adjustments/Striker
Adjustment.
7. For additional information on body margins, refer to Body and Frame / Specifications / Panel
Gap Tolerances.
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 09-19-18 > Oct > 09 > Body - Rear
Cargo Door(s) Rattle
Rear Door Latch: Customer Interest Body - Rear Cargo Door(s) Rattle
TSB 09-19-18
10/05/09
REAR CARGO DOOR RATTLE - BUILT BEFORE 6/1/2009

ISSUE Some 2010 Transit Connect vehicles built before 6/1/2009 may exhibit a rattle noise coming
from the rear cargo doors. This may be due to metal on metal contact between one or more of the
rear cargo door(s) latches and strikers - left hand (LH) upper latch, right hand (RH) upper latch or
LH lower latch.
SERVICE PROCEDURE
1. Align the rear cargo doors with the body, per Workshop Manual (WSM), Section 501-03.
2. Apply Krytox grease (Rotunda part number 164-R4906 - 1-800-768-8632 option 3) to the latches
as illustrated. (Figures 1 and 2)
3. Use chassis ears to determine that the cargo door latch is the source of the noise by connecting
the leads to the cargo door strikers.
a. If the noise is resolved, no further action is required.
b. If the noise is still present, proceed to Step 4.

Information > Technical Service Bulletins > Customer Interest for Rear Door Latch: > 09-19-18 > Oct > 09 > Body - Rear
Cargo Door(s) Rattle > Page 4969
4. Replace the affected latch or latches per WSM, Section 501-14.
Parts Block
091918A 2010 Transit Connect: 1.1 Hrs.
Includes Time To Align Rear Cargo Doors, Grease Latches, Connect Chassis Ears And Road Test.
Can Be Used With Operations B, C, And D (Do Not Use With 22600D)
Replace Upper RH Side Door Latch, Includes Time To Remove and Install Lower RH Side Door
Latch. Can Be Used With Operation A, C, and D (Do Not Use With 22600D)
Replace Lower LH Side Door Latch. Can Be Used With Operation A, B, and D (Do Not Use With
22600D)
Replace Upper LH Side Door Latch. Can Be Used With Operation A, B, and C (Do Not Use With
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 09-19-18 > Oct > 09 >
Body - Rear Cargo Door(s) Rattle
Rear Door Latch: All Technical Service Bulletins Body - Rear Cargo Door(s) Rattle
TSB 09-19-18
10/05/09

LH lower latch.
SERVICE PROCEDURE

Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > 09-19-18 > Oct > 09 >
Body - Rear Cargo Door(s) Rattle > Page 4975
Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Latch: > Page 4976
Rear Door Latch: By Symptom
TSB 09-19-18
10/05/09
LH lower latch.
SERVICE PROCEDURE

Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
TSB 09-19-18
10/05/09

LH lower latch.
SERVICE PROCEDURE

Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Rear Door Latch: Adjustments
Door Handle to Latch Rod Adjustment
NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door
hard to open from the outside door handle, or the outside door handle to not sit flush in the closed
position.
NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and
linkages must be installed on the door.
1. Raise the door glass to the full-up position.
4. Open the clip and disconnect the exterior door handle actuating rod.
5. Position the actuating rod and latch actuating lever in a neutral position.
6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever.
Reinstall the exterior door handle actuating rod back into the clip.
7. Close the clip and test the system to make sure that the exterior door handle is operating
correctly.
8. Reseal the water shield.
9. Install the door trim panel.

Rear Door Latch: Procedures
Latch Lubrication
1. Open the door.
2. Using a screwdriver, fully close the latch (2 clicks).
3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using either the interior or exterior door handle.
5. Open and close the door several times to circulate the lubricant inside the latch.
6. Wipe off any excess grease.
Rear Door Latch: Removal and Replacement
Left Rear Door
Right Rear Door

Rear Door Latch - Upper, RH
Rear Door Latch - Upper, RH
1. Remove the lower RH rear door latch. For additional information, refer to Rear Door Latch -
Center, RH See: Rear Door Latch - Center, RH.
2. NOTE: The draw cord is used to aid the installation of the latch. It is used to pull the latch back
up into the door.
Attach a draw cord to the upper door latch.
3. Remove the 2 right rear door upper latch bolts.
4. Lower the right rear door upper latch into the door and remove.
Rear Door Latch - Center, RH
Rear Door Latch - Center, RH

1. Remove the rear door lock cylinder. For additional information, refer to Door Lock Cylinder -
Rear See: Locks/Door Locks/Door Lock
Cylinder/Service and Repair/Removal and Replacement/Door Lock Cylinder - Rear.
2. Pull out on the latch lock knob to remove it.
3. Disconnect the right rear center door latch electrical connector.
4. Open the clip and disconnect the exterior rear door handle actuating rod.
5. Remove the 4 right rear door center latch bolts.
6. Remove the right rear door upper latch cable from the center door latch.
7. Remove the right rear door center latch from the door.
Rear Door Latch - Upper, LH
Rear Door Latch - Upper, LH

1. Remove the left rear door trim panel.
2. Open the clip and disconnect the left rear door upper latch cable from the remote control.
3. NOTE: The draw cord is used to aid the installation of the latch. It is used to pull the latch back
up into the door.
Attach a draw cord to the upper door latch.
4. Remove the 2 left rear door upper latch bolts.
5. Lower the left rear door upper latch into the door and remove.
Rear Door Latch - Lower, LH
Rear Door Latch - Lower, LH

1. Remove the left rear door trim panel.
2. Remove the 2 left rear door lower latch bolts.
3. Open the clip and disconnect the left rear door upper latch cable from the remote control.
4. Remove the left rear door handle screw and handle.
5. Remove the 2 left rear door remote control bolts.
6. Remove the left rear door lower latch from the door.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System
Information > Technical Service Bulletins > Customer Interest for Rear Door Striker: > 09-19-18 > Oct > 09 > Body - Rear
Cargo Door(s) Rattle
Rear Door Striker: Customer Interest Body - Rear Cargo Door(s) Rattle
TSB 09-19-18
10/05/09

LH lower latch.
SERVICE PROCEDURE

Information > Technical Service Bulletins > Customer Interest for Rear Door Striker: > 09-19-18 > Oct > 09 > Body - Rear
Cargo Door(s) Rattle > Page 4996
Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Striker: > 09-19-18 > Oct > 09 >
Rear Door Striker: All Technical Service Bulletins Body - Rear Cargo Door(s) Rattle
TSB 09-19-18
10/05/09

LH lower latch.
SERVICE PROCEDURE

Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Striker: > 09-19-18 > Oct > 09 >
Body - Rear Cargo Door(s) Rattle > Page 5002
Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Striker: > Page 5003
Rear Door Striker: By Symptom
TSB 09-19-18
10/05/09
LH lower latch.
SERVICE PROCEDURE

Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
TSB 09-19-18
10/05/09

LH lower latch.
SERVICE PROCEDURE

Parts Block
22600D)
22600D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
V43286 42
Disclaimer
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Service and Repair > Exterior Sliding Door Handle
Sliding Door Handle: Service and Repair Exterior Sliding Door Handle
Exterior Sliding Door Handle
Removal
1. Remove the sliding door interior door handle caps.
2. Remove the sliding door interior door handle bolts and position the handle aside.
3. Remove the exterior sliding door handle bezel screw.
4. Remove the exterior sliding door handle bezel.
5. Remove the exterior sliding door handle.
1. Slide the exterior sliding door handle toward the front of the vehicle to disengage it from the
exterior front door handle reinforcement.
2. Pull outward on the exterior sliding door handle.
Installation
1. Install the exterior sliding door handle.

Component Information > Service and Repair > Exterior Sliding Door Handle > Page 5012
2. Slide the exterior sliding door handle across the exterior door handle actuating lever.
2. Install the exterior sliding door handle bezel.
3. Install the exterior sliding door handle bezel screw.
4. Install the sliding door interior door handle and bolts.
5. Install the sliding door interior door handle caps.

Sliding Door Handle: Service and Repair Sliding Door Handles, Locks and Latches - Exploded
View
Sliding Door Handles, Locks and Latches - Exploded View
Sliding Door Handle: Service and Repair Door Handle Reinforcement - Exterior, Sliding Door
Door Handle Reinforcement - Exterior, Sliding Door
1. Remove the exterior sliding door handle. For additional information, refer to Exterior Sliding Door
Handle See: Exterior Sliding Door Handle.
2. Pull the sliding door lock knob to remove it.
3. Remove the sliding door trim panel.
4. Position the watershield aside.
5. Remove the exterior sliding door handle seals.
6. Remove the exterior sliding door handle reinforcement nut.
7. Push the exterior sliding door handle reinforcement into the door.
8. Remove the exterior sliding door handle reinforcement cable from the guide clip.
9. Remove the 3 sliding door latch bolts and position the latch down into the door.

10. Remove the exterior sliding door handle cable from the latch.
11. Remove the exterior sliding door handle reinforcement and cable assembly from the door.

Sliding Door Handle: Service and Repair Interior Door Handle - Sliding Door
Interior Door Handle - Sliding Door
4. Remove the 3 sliding door latch bolts and position the latch down into the door.
5. Remove the interior sliding door handle cable from the latch.
6. Remove the interior sliding door handle cable from the guide clip.
7. Remove the interior sliding door handle caps.
8. Remove the 2 interior sliding door handle bolts.
9. Remove the interior sliding door handle and cable assembly from the door.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch >
System Information > Service and Repair > Sliding Door Latch
Sliding Door Latch: Service and Repair Sliding Door Latch
Sliding Door Latch
4. Disconnect the door latch electrical connector.
5. Remove the 4 door latch wiring harness guide pins.
6. Remove the 3 sliding door latch bolts.

7. Remove the outside door handle cable from the latch.
8. Remove the inside door handle cable from the latch.
9. Remove the sliding door latch from the door.

System Information > Service and Repair > Sliding Door Latch > Page 5020
Sliding Door Latch: Service and Repair Sliding Door Handles, Locks and Latches - Exploded View
Sliding Door Handles, Locks and Latches - Exploded View

Sliding Door Latch: Service and Repair Sliding Door Travel Limiting Latch
Sliding Door Travel Limiting Latch
Removal
1. Remove the RH sliding door track cover retaining nuts.
2. Remove the RH sliding door track cover.
3. Remove the sliding door travel limiting latch.
- Remove the sliding door travel limiting latch bolts.

- Disconnect the sliding door travel limiting latch cable assembly.
Installation
1. Install the sliding door travel limiting latch.
- Connect the sliding door travel limiting latch cable assembly.
- Tighten bolts to 12Nm (106 lb-in).
2. Install the RH sliding door track cover.
3. Install the RH sliding door track cover retaining nuts.
- Tighten to 5Nm (44 lb-in).

Sliding Door Latch: Service and Repair Sliding Door Travel Limiting Latch Cable Assembly
Sliding Door Travel Limiting Latch Cable Assembly
Removal
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.
1. Remove the sliding door travel limiting latch. For additional information, refer to Sliding Door
Travel Limiting Latch See: Sliding Door Travel
Limiting Latch.
2. Remove the fuel tank filler cap and tether.
- Remove the scrivet.

- Remove the fuel tank filler cap.
3. NOTE: Remove as an assembly the fuel tank filler pipe housing, the fuel filler door and the
sliding door travel limiting latch cable assembly.
Remove the fuel tank filler pipe housing.
- Remove the scrivet.
- Remove the fuel tank filler pipe housing.
4. NOTE: The sliding door travel limiting latch cable assembly Is retained on all four sides of the
fuel tank filler pipe housing.
Remove the sliding door travel limiting latch cable assembly from the fuel tank filler pipe housing.
Installation
1. Install the sliding door travel limiting latch cable assembly to the fuel tank filler pipe housing.
2. Install the fuel tank filler pipe housing.
- Install the scrivet.
3. Install the fuel tank filler cap and tether.
- Install the scrivet.

4. Install the sliding door travel limiting latch. For additional information, refer to Sliding Door Travel
Limiting Latch See: Sliding Door Travel
Limiting Latch.
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Window Glass
Sliding Door Window Glass: Service and Repair
Window Glass - Sliding Door
Removal
1. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield
pinchweld area.
- Use a clean shop towel or oil-free, compressed air.

> System Information > Service and Repair > Page 5027
2. NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when
cutting.
3. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
instruction may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer or otherwise
damage the pinchweld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the
glass. This will leave the entire urethane adhesive bead on the pinchweld and allow a dry fit of the
replacement sliding door glass.
NOTE: Some resistance may be encountered when cutting through the glass locating pegs in the
corners of the glass.
Insert the Deluxe Windshield Removal Tool at the upper center of the sliding door glass and work
toward the bottom corners.
4. Insert the Deluxe Windshield Removal Tool into the bottom of the urethane adhesive and cut
from corner to corner.
5. Carefully remove the sliding door glass from the vehicle and place on a stable work surface.
6. Remove and discard the sliding door window glass weatherstrip.
Installation
1. Dry-fit the sliding door glass on the existing urethane adhesive bead on the pinch weld.
- Position the sliding door glass on the pinch weld.
- Center the glass in the opening.
- Make alignment marks with tape or non-staining grease pencil on the sliding door glass and the
body.
2. After the dry-fit alignment, remove the glass from the body opening and place on a stable work
surface with the interior side of the glass facing
upward.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left
unrepaired may reduce the structural integrity of the vehicle. Failure to follow this instruction may
result in serious injury to vehicle occupant(s).
NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer
and urethane adhesive.
NOTE: Carefully remove the remaining part of the locating pegs from the sliding door window glass
opening.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.08 in) base of
original equipment urethane adhesive on the pinch weld.
> System Information > Service and Repair > Page 5028
4. Using a clean shop towel, brush or oil-free, compressed air, clean the pinch weld area around
the existing urethane adhesive. Remove any foreign
material or water that may have entered during glass removal.
5. If reinstalling the same sliding door glass, remove the remaining urethane adhesive from the
glass leaving a thin layer to bond with the new
urethane adhesive bead.
6. Clean the inside of the sliding door glass surface with glass cleaner.
- Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.
7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and
glass primer. Do not mix different brands of urethane
adhesive and glass primer. Refer to the Material Chart in this procedure.
If installing a new sliding door glass, apply glass primer according to manufacturer's instructions.
Allow at least 6 minutes to dry.
8. Install a new sliding door window glass weatherstrip.
9. NOTE: Use either the Air Caulking Gun or a high-ratio, electric or battery-operated caulk gun
that will apply the urethane adhesive with less
effort and continuous bead.
NOTE: The sliding door glass must be positioned within 10 minutes of applying the urethane
adhesive.
Apply a uniform bead of urethane adhesive of between 8 mm (0.314 in) and 10 mm (0.393 in) in
height on top of the existing trimmed urethane adhesive bead on the pinch weld, starting and
ending at the bottom of the sliding door glass opening near the center, making sure there are no
gaps in the bead.
10. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow urethane
adhesive manufacturer's curing directions.
Inadequate or incorrect curing of the urethane adhesive seal will adversely affect glass retention.
Failure to follow these instructions may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the sliding door glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the sliding door glass on the pinch weld.
11. Using suitable tape, secure the sliding door window glass in the correct position until the
urethane adhesive has cured.
12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or
water leaks.
After the urethane adhesive has cured, check the sliding door glass seal for air or water leaks
through the urethane adhesive bead and add urethane adhesive as necessary.
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock Cylinder > Component
Fuel Door Lock Cylinder: Service and Repair
Fuel Door Lock Cylinder
Assembly
Select the required tumblers according to the key cut depths for each position from A through F
according to the following rules:
- 3 "D" tumblers have to be used.
- "D" tumblers cannot be used in position A or F.
- At least one "4" tumbler has to be used.

Install the fuel door lock cylinder tumblers and spacers into the fuel door lock cylinder barrel as
follows:
3. Apply the multi-purpose grease on the lock cylinder barrel in and around the locking pin slot.
5. Slide the fuel door lock cylinder body onto the fuel door lock cylinder barrel.
6. Install the shutter housing into the fuel door lock cylinder body.
7. Install the shutter assembly.
1. Slide the pin through the shutter spring.

2. Install the shutter pin and spring into the shutter housing.
3. Install the shutter over the spring and down into the housing.
8. Apply a small amount of the multi-purpose grease on the fuel door keyway plate where it
contacts the shutter assembly.
9. NOTE: The smooth side of the keyway plate faces outwards.
While pushing down on the shutter, install the keyway plate onto the fuel door lock cylinder body.
10. Using a suitable tool (such as a chisel), crimp the fuel door lock cylinder body to secure the
keyway plate in place.
11. Stick the water seal to the face of the keyway plate.
12. Install the fuel door lock cylinder lock lever and circlip.
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Service and Repair
Hood Latch: Service and Repair
Hood Latch
NOTE: Radiator grille shown removed for clarity.

1. Remove the 4 upper radiator grille screws.
2. Gently pull up on the upper radiator grille to gain access to the hood latch bracket bolts.
3. Remove the 4 hood latch bracket bolts and remove the hood latch assembly.
4. NOTE: Mark the position of the hood latch prior to removing the hood latch bolts.
Remove the 3 hood latch bolts.
5. Remove the hood latch.
- Slide the hood latch lock cylinder off the hood latch.

Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip >
Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 11-3-10 > Mar
> 11 > Body - Various Water Leak Issues
Trunk / Liftgate Weatherstrip: Customer Interest Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

> 11 > Body - Various Water Leak Issues > Page 5048
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: >
11-3-10 > Mar > 11 > Body - Various Water Leak Issues
Trunk / Liftgate Weatherstrip: All Technical Service Bulletins Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

11-3-10 > Mar > 11 > Body - Various Water Leak Issues > Page 5059
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Technical Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water
Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Leak Issues > Page 5074
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body -
Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Various Water Leak Issues > Page 5085
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 5091
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Cowl Panel Grille
Systems.


All vehicles

Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Fender Splash Shield
Front Fender Liner: Service and Repair Fender Splash Shield
Fender Splash Shield
3. Remove the 2 fender splash shield bolts.
4. Remove the 5 fender splash shield screws.
5. Remove the fender splash shield.

Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Fender Splash Shield > Page 5112
Front Fender Liner: Service and Repair Front End Body Panels - Exploded View
Front End Body Panels - Exploded View
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information >
Body / Frame Mount Bushing: Description and Operation
For body dimension specifications, refer to Body and Frame / Specifications / Dimensions.
Ford Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Specifications
Front Subframe: Specifications
SPECIFICATIONS
> Page 5121
Front Subframe: Description and Operation
For body dimension specifications, refer to Specifications / Dimensions.

> Page 5122
Front Subframe: Service and Repair
Subframe - Front
NOTE: The front bumper cover and the RH/LH brake assemblies have been removed for clarity.
Removal
1. Center the steering wheel, remove the ignition key and lock the steering wheel in position.
2. Disconnect the steering column shaft from the steering column coupling shaft.
- Discard the bolt.
3. Remove the front wheels and tires. For additional information, refer to Wheels and Tires.
4. NOTICE: Leave the tie-rod end nuts in place to protect the ball joint studs or damage to the
vehicle may occur.
> Page 5123
Loosen, but do not remove, the tie-rod end nut on both sides.
5. Using the Tie-Rod End Remover, disconnect the tie-rod end from the wheel knuckle on both
sides.
- Remove the tie-rod end nuts.
6. Remove the stabilizer bar link nuts on both sides and position the stabilizer bar links and ABS
wiring brackets aside.
7. Remove the power steering line retainer bolt and retainer from the steering gear.
8. Remove the power steering line clamp clockwise, and disconnect the 2 power steering lines from
the power steering gear.
- Allow the remaining oil to drain into a suitable container.
9. Remove the roll restrictor bolt.
10. Using a suitable support table, support the front subframe.
11. Index-mark the location of the subframe to the vehicle before removal.
12. NOTE: Separate the ball joint from the wheel knuckle as the front subframe is lowered.
Disconnect the lower arm ball joint from the wheel knuckle on both sides.
- Remove the 2 lower arm ball joint heat shields.
13. Remove the 6 subframe bolts.
14. Remove the front subframe.
Installation
1. Position the subframe to the vehicle.
2. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.
Loosely install the 6 subframe lower bolts.
- Align the index marks made before removal.
- Tighten the front subframe bolts to 125 Nm (93 lb-ft).
- Tighten the rear subframe bolts to 200 Nm (148 lb-ft).
3. Remove the support table.
4. Install the roll restrictor bolt.
5. Position the lower arm ball joint to the wheel knuckle on both sides and install the nuts.
6. NOTE: New O-ring seals must be installed any time the lines are disconnected from the steering
gear.
Using the Teflon(R) Seal Installer Set, install new O-ring seals onto the power steering lines.
7. Connect the power steering lines to the power steering gear, rotate the power steering line
clamp counterclockwise and loosely install the bolt.
8. Install the power steering line retainer and bolt.
9. Tighten the power steering line clamp bolt to 18 Nm (159 lb-in).
10. Install the 2 stabilizer bar links, ABS wiring brackets and the nuts.

> Page 5124
11. WARNING: Do not reuse a tie rod-to-wheel knuckle nut. This can result in nut failure and loss
of steering control. Failure to follow this
Install the 2 tie-rod ends and the nuts. -
12. Install the front wheels and tires. For additional information, refer to Wheels and Tires.
13. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss
of vehicle control. Failure to follow this
Connect the steering column shaft to the steering column coupling shaft and install the bolt. -
14. Fill and bleed the power steering system. For additional information, refer to Steering.
15. Check the front end alignment and adjust as necessary. For additional information, refer to
Suspension &/or Alignment.
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille
Opening Panel Reinforcement
Grille: Service and Repair Radiator Grille Opening Panel Reinforcement
Radiator Grille Opening Panel Reinforcement
2. Remove the headlamps.
3. Remove the hood latch assembly. For additional information, refer to Doors, Hood and Trunk
&/or Locks.
4. Remove the LH and RH radiator side air deflector screws and remove the radiator air deflectors.
5. Remove the fender-to-radiator grille opening panel reinforcement bolts.

6. Remove the radiator grille opening panel reinforcement upper bolts.
7. Remove the radiator grille opening panel reinforcement.

Opening Panel Reinforcement > Page 5129
Grille: Service and Repair Radiator Grille
Radiator Grille
Upper radiator grille
2. Remove the 9 upper radiator grille reinforcement star washers.
3. Remove the 4 upper radiator grille reinforcement screws.

Opening Panel Reinforcement > Page 5130
4. Remove the upper radiator grille reinforcement.
5. Remove the 6 upper radiator grille star washers.
6. Press downward on the upper radiator grille lower clips to release the upper radiator grille from
the front bumper cover.
Lower radiator grille
7. Press outward on the lower radiator grille tabs to release the lower radiator grille from the
bumper cover.
All grilles

Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Cargo Cover > Component Information > Technical
Service Bulletins > Customer Interest for Cargo Cover: > 10-1-10 > Feb > 10 > Interior - Rubber Cargo Mat Offensive Odors
Cargo Cover: Customer Interest Interior - Rubber Cargo Mat Offensive Odors
TSB 10-1-10
02/01/10
BLACK RUBBER CARGO MAT OFFENSIVE SMELL
ISSUE Some 2010 Transit Connect Vans may emit an offensive odor to the customer, coming from
the black rubber cargo mat, in hot ambient temperatures.
SERVICE PROCEDURE
To reduce the odor until it dissipates naturally, we recommend the following:
1. Place about 1 lb. of charcoal briquettes in an open, shallow container.
2. Place the container in the middle of the cargo compartment.
3. Close all of the doors and windows of the van and keep them closed for 24 hours. The charcoal
will absorb a great deal of the odor.
4. After 24 hours, dispose of the charcoal as required by local regulations.
5. Soak a piece of cloth with Pine-Sol(R) cleaner (do not dilute the Pine-Sol(R) cleaner with water)
and wipe a very thin coat of Pine-Sol(R) cleaner on
the mat.
6. Allow the mat to dry and air vehicle out for another 24 hours.
MT100110 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
7013000 42
Disclaimer
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Cargo Cover > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cargo Cover: > 10-1-10 > Feb > 10 > Interior - Rubber Cargo Mat
Offensive Odors
Cargo Cover: All Technical Service Bulletins Interior - Rubber Cargo Mat Offensive Odors
TSB 10-1-10
02/01/10
BLACK RUBBER CARGO MAT OFFENSIVE SMELL
ISSUE Some 2010 Transit Connect Vans may emit an offensive odor to the customer, coming from
the black rubber cargo mat, in hot ambient temperatures.
SERVICE PROCEDURE
To reduce the odor until it dissipates naturally, we recommend the following:
1. Place about 1 lb. of charcoal briquettes in an open, shallow container.
2. Place the container in the middle of the cargo compartment.
3. Close all of the doors and windows of the van and keep them closed for 24 hours. The charcoal
will absorb a great deal of the odor.
4. After 24 hours, dispose of the charcoal as required by local regulations.
5. Soak a piece of cloth with Pine-Sol(R) cleaner (do not dilute the Pine-Sol(R) cleaner with water)
and wipe a very thin coat of Pine-Sol(R) cleaner on
the mat.
6. Allow the mat to dry and air vehicle out for another 24 hours.
MT100110 Use SLTS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
7013000 42
Disclaimer
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical
Service Bulletins > Customer Interest for Carpet: > 11-1-4 > Jan > 11 > Interior - Gray Colored Cargo Mat Bubbling In High
Heat
Carpet: Customer Interest Interior - Gray Colored Cargo Mat Bubbling In High Heat
TSB 11-1-4
01/25/11
GRAY CARGO MAT BUBBLE CONDITION ABOVE 38 DEGREES C (100 DEGREES F)
ISSUE Some 2010 Transit Connect vans which are equipped with a gray colored cargo mat and
built on or after 5/1/2010 may exhibit a bubbling condition in ambient temperatures above 38
degrees Celsius (100 degrees Fahrenheit).
SERVICE PROCEDURE
To correct the condition, the gray mat should be replaced with a black mat.
Gray Mat Removal
1. Remove the two (2) piece front plastic trim. Discard trim panels and screws. (Figure 1-A)
2. Loosen left and right sliding door scuff trim panels. (Figure 1-B)
a. Scuff panels will not be completely removed.
b. Door weather-stripping does not need to be removed.
(1) Remove the three (3) push pins holding the scuff panel to the floor and discard push pins.
(2) Loosen, but do not completely remove, the three (3) screws. (Figure 1-B)
Heat > Page 5153
3. Remove rear trim molding. Discard molding and screws. (Figure 2-A)
4. Remove and discard cargo floor mat. (Figure 1-C)
5. Remove cargo floor extension. Set aside extension and bolts.
Black Mat Installation
1. Locate cargo floor extension removed in Gray Mat Removal Step 5.
a. Remove all nine (9) plastic ribs from floor and discard. The ribs may be removed by drilling out
each rivet 4.75 mm (3/16") drill bit or cutting
the exposed rivet shaft crown from the underside of the extension and press the rivet free. Rivet
removal should occur outside of the vehicle so that the vehicle is not exposed to metal shavings.
(Figure 3-A)
b. Apply Motorcraft(R) Anti-Corrosion Coating to removed rib rivet and trim molding screw holes 18
rib and 10 trim holes.
2. On the rear door sill, locate the five (5) holes from the rear molding attachment.
a. Wipe door sill with a clean rag.
b. Apply Motorcraft® Anti-Corrosion Coating to the five (5) holes.

Heat > Page 5154
c. Apply one sealer patch to each former attachment hole, five (5) places. (Figure 4-A)
(1) The patch should be centered directly over the each hole but remain hidden under the new
rubber cargo mat. (Figure 5-A)
3. Cargo floor extension reinstall the rib less cargo floor extension with saved six (6) bolts. Apply
Motorcraft® Threadlock and Sealer to each bolt prior
to installing. Torque to 107 N.m (24 ft-lb). (Figure 6)
4. Position cargo floor mat in vehicle, ensuring that the mat is centered fore-and-aft as well as
side-to-side.
a. Align the mat at both sliding door scuff panel rear push pin holes, insert a rod/pin to hold mat in
position to assist with overall proper alignment.
Ensure mat is flat and pulled tight across open floor span.
b. Carefully position mat under each sliding door scuff trim panel. Do not install scuff panel
hardware at this time.
Heat > Page 5155
5. Position and install the front transition molding and nine (9) screws. Torque tight plus 1/4 turn.
(Figure 7-A)
a. Self tapping screws should run through the rubber floor mat into the extension member. Start at
left and right rear corners will assist with proper
molding alignment. (Figure 7-B)
b. Vacuum all metal shavings at sliding door zones.
6. Ensure mat is smooth under sliding door scuff trim panels. Install new push pins. Tighten all
screws. Torque hand-tight. (Figure 8)
7. With mat in the correct position over rear sill, align metal rear sill molding. Center punch and
mark the four outboard holes. Install rear transition
molding. Torque hand-tight plus 1/4 turn. If center screw has retention problem, apply small amount
of Motorcraft(R) Threadlock and Sealer and reinstall. (Figure 9)
a. Vacuum all metal shavings from rear door zone.
Heat > Page 5156
Replace Cargo Mat (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6113046 34
Disclaimer
Service Bulletins > All Technical Service Bulletins for Carpet: > 11-1-4 > Jan > 11 > Interior - Gray Colored Cargo Mat
Bubbling In High Heat
Carpet: All Technical Service Bulletins Interior - Gray Colored Cargo Mat Bubbling In High Heat
TSB 11-1-4
01/25/11
GRAY CARGO MAT BUBBLE CONDITION ABOVE 38 DEGREES C (100 DEGREES F)
ISSUE Some 2010 Transit Connect vans which are equipped with a gray colored cargo mat and
built on or after 5/1/2010 may exhibit a bubbling condition in ambient temperatures above 38
degrees Celsius (100 degrees Fahrenheit).
SERVICE PROCEDURE
To correct the condition, the gray mat should be replaced with a black mat.
Gray Mat Removal
1. Remove the two (2) piece front plastic trim. Discard trim panels and screws. (Figure 1-A)
2. Loosen left and right sliding door scuff trim panels. (Figure 1-B)
a. Scuff panels will not be completely removed.
b. Door weather-stripping does not need to be removed.
(1) Remove the three (3) push pins holding the scuff panel to the floor and discard push pins.
(2) Loosen, but do not completely remove, the three (3) screws. (Figure 1-B)
Bubbling In High Heat > Page 5162
3. Remove rear trim molding. Discard molding and screws. (Figure 2-A)
4. Remove and discard cargo floor mat. (Figure 1-C)
5. Remove cargo floor extension. Set aside extension and bolts.
Black Mat Installation
1. Locate cargo floor extension removed in Gray Mat Removal Step 5.
a. Remove all nine (9) plastic ribs from floor and discard. The ribs may be removed by drilling out
each rivet 4.75 mm (3/16") drill bit or cutting
the exposed rivet shaft crown from the underside of the extension and press the rivet free. Rivet
removal should occur outside of the vehicle so that the vehicle is not exposed to metal shavings.
(Figure 3-A)
b. Apply Motorcraft(R) Anti-Corrosion Coating to removed rib rivet and trim molding screw holes 18
rib and 10 trim holes.
2. On the rear door sill, locate the five (5) holes from the rear molding attachment.
a. Wipe door sill with a clean rag.
b. Apply Motorcraft® Anti-Corrosion Coating to the five (5) holes.

c. Apply one sealer patch to each former attachment hole, five (5) places. (Figure 4-A)
(1) The patch should be centered directly over the each hole but remain hidden under the new
rubber cargo mat. (Figure 5-A)
3. Cargo floor extension reinstall the rib less cargo floor extension with saved six (6) bolts. Apply
Motorcraft® Threadlock and Sealer to each bolt prior
to installing. Torque to 107 N.m (24 ft-lb). (Figure 6)
4. Position cargo floor mat in vehicle, ensuring that the mat is centered fore-and-aft as well as
side-to-side.
a. Align the mat at both sliding door scuff panel rear push pin holes, insert a rod/pin to hold mat in
position to assist with overall proper alignment.
Ensure mat is flat and pulled tight across open floor span.
b. Carefully position mat under each sliding door scuff trim panel. Do not install scuff panel
hardware at this time.
5. Position and install the front transition molding and nine (9) screws. Torque tight plus 1/4 turn.
(Figure 7-A)
a. Self tapping screws should run through the rubber floor mat into the extension member. Start at
left and right rear corners will assist with proper
molding alignment. (Figure 7-B)
b. Vacuum all metal shavings at sliding door zones.
6. Ensure mat is smooth under sliding door scuff trim panels. Install new push pins. Tighten all
screws. Torque hand-tight. (Figure 8)
7. With mat in the correct position over rear sill, align metal rear sill molding. Center punch and
mark the four outboard holes. Install rear transition
molding. Torque hand-tight plus 1/4 turn. If center screw has retention problem, apply small amount
of Motorcraft(R) Threadlock and Sealer and reinstall. (Figure 9)
a. Vacuum all metal shavings from rear door zone.
Replace Cargo Mat (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6113046 34
Disclaimer
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console - Floor
Console: Service and Repair Console - Floor
Console - Floor
Rear floor console section
1. Remove the LH and RH seats. For additional Information, refer to Seats.
3. Place the selector lever in the NEUTRAL position.
4. Remove the 2 rear floor console section screw covers.
5. Remove the 2 rear floor console screws.

Repair > Console - Floor > Page 5170
1. Lift the rear of the panel upward, releasing the rear retaining clips.
2. Pull the panel toward the rear of the vehicle releasing the front retaining clips.
7. Remove the 2 front-to-rear floor console screws.
8. Remove the rear section of the floor console in the following sequence.
1. Lift the rear section of the floor console upward and disconnect the electrical connectors.
2. Guide the park brake lever boot over the park brake handle.
3. NOTE: The power window switch electrical connectors are interchangeable with the switches; be
sure to mark the connectors to make sure of
proper installation.
Disconnect the electrical connectors, if equipped with power windows.
Front floor console section

9. Pull the lower sides of the front floor console outward releasing the 4 pin-type retainers.
10. NOTE: To aid in the installation, it may be necessary to rotate the controls to align the cables
with the temperature control and mode control
doors.
Detach the temperature control and mode control cables at the heater core and evaporator core
housing.
11. Pull the front floor console section toward the rear of the vehicle, releasing the retaining clips
from the instrument panel. Disconnect the 2
electrical connectors from the HVAC controller.
12. Remove the front floor console section.
- To install, make sure to align the retaining clips to the adjacent retaining clip holes.
Console: Service and Repair Console - Overhead
Console - Overhead
1. NOTICE: When prying on a component, a non-marring tool must be used or damage to the
component may occur.
Remove the front dome lamp in the following sequence.
1. With a non-marring tool, pry the front dome lamp downward to release from the headliner.
2. Remove the LH and RH sun visors and the sun visor clips.
3. Remove the overhead console screws and bolts in the following sequence.
1. Remove the 2 front screws through the front dome lamp opening.
2. Remove the 2 front bolts through the sun visor mounting openings.
3. Remove the 2 overhead console cargo net bracket bolts.
4. NOTICE: To avoid damaging the overhead console, an assistant is required to support the
instrument panel when carrying out this
step.
Remove the 2 rear bolts and the overhead console.
- To install, make sure to align the guide pin to the adjacent hole.
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering and
Repowering

to Battery.
Repowering > Page 5178
Deactivation
latches.
impact sensor(s).
to Battery.

connectors.

Reactivation
refer to Battery.
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical
Service Bulletins > Recalls for Headliner: > 10C13 > Jul > 10 > Recall - Headliner Pushpin Non-Compliance
Technical Service Bulletin # 10C13 Date: 100707
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on July 7, 2010.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on July 7, 2010. Owner names and
addresses will be available by July 28, 2010.
NOTE:
Service Bulletins > Recalls for Headliner: > 10C13 > Jul > 10 > Recall - Headliner Pushpin Non-Compliance > Page 5190
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this recall.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION

^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Related damage must be claimed on a repair line that is separate from the repair line on which
the FSA is claimed. Related damage requires prior approval from the Special Service Support
Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION

Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50422.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
On some of the affected vehicles the headliner pushpin at the B-pillar may not absorb sufficient
energy to conform to the requirements specified by Federal Motor Vehicle Safety Standard
(FMVSS) No.201 - Occupant Protection in Interior Impact.
SERVICE PROCEDURE
1. Remove the existing headliner pushpins (one per side) located directly above the right and left
upper B-pillar trim panels. See Figure 1.
2. Install the revised pushpins.

Service Bulletins > Recalls for Headliner: > NHTSA10V316000 > Jul > 10 > Recall 10V316000: Headliner Push Pin
Replacement
Headliner: Recalls Recall 10V316000: Headliner Push Pin Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Transit Connect 2010 MANUFACTURER: Ford
Motor Company
MFR'S REPORT DATE: July 06, 2010
NHTSA CAMPAIGN ID NUMBER: 10V316000
NHTSA ACTION NUMBER: N/A COMPONENT: Structure: Body: Roof and Pillars
POTENTIAL NUMBER OF UNITS AFFECTED: 33728
SUMMARY: Ford is recalling certain model year 2010 Transit Connect vehicles manufactured from
December 5, 2008 through May 31, 2010 for failing to meet the minimum requirements of Federal
Motor Vehicle Safety Standard No. 201, "Occupant Protection in Interior Impact." During vehicle
testing the vehicle exceeded head injury criteria requirements set by the standard. The headliner
retention pushpin located on the headliner above the b-pillar trim on both the left and right side of
the vehicles needs to be replaced.
CONSEQUENCE: In the event of a vehicle crash, an occupant could be at an increased risk of

injury.
REMEDY: Ford will notify owners and dealers will repair the vehicles free of charge. The safety
recall is expected to begin on or about July 19, 2010. Owners may contact Ford Motor Company at
1-866-436-7332.
NOTES: Ford's recall campaign number is 10C13. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Service Bulletins > All Technical Service Bulletins for Headliner: > 10C13 > Jul > 10 > Recall - Headliner Pushpin
Non-Compliance
Technical Service Bulletin # 10C13 Date: 100707
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on July 7, 2010.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website on July 7, 2010. Owner names and
addresses will be available by July 28, 2010.
NOTE:
Non-Compliance > Page 5203
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected customers whose vehicles are not on your VIN list but
are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available)
and schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this recall.
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
Refunds are not authorized for this program.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Related damage must be claimed on a repair line that is separate from the repair line on which
the FSA is claimed. Related damage requires prior approval from the Special Service Support
Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this recall is 50422.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
On some of the affected vehicles the headliner pushpin at the B-pillar may not absorb sufficient
energy to conform to the requirements specified by Federal Motor Vehicle Safety Standard
(FMVSS) No.201 - Occupant Protection in Interior Impact.
SERVICE PROCEDURE
1. Remove the existing headliner pushpins (one per side) located directly above the right and left
upper B-pillar trim panels. See Figure 1.
2. Install the revised pushpins.

Service Bulletins > All Technical Service Bulletins for Headliner: > NHTSA10V316000 > Jul > 10 > Recall 10V316000:
Headliner Push Pin Replacement
Headliner: All Technical Service Bulletins Recall 10V316000: Headliner Push Pin Replacement
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Transit Connect 2010 MANUFACTURER: Ford
Motor Company
MFR'S REPORT DATE: July 06, 2010
NHTSA CAMPAIGN ID NUMBER: 10V316000
NHTSA ACTION NUMBER: N/A COMPONENT: Structure: Body: Roof and Pillars
POTENTIAL NUMBER OF UNITS AFFECTED: 33728
SUMMARY: Ford is recalling certain model year 2010 Transit Connect vehicles manufactured from
December 5, 2008 through May 31, 2010 for failing to meet the minimum requirements of Federal
Motor Vehicle Safety Standard No. 201, "Occupant Protection in Interior Impact." During vehicle
testing the vehicle exceeded head injury criteria requirements set by the standard. The headliner
retention pushpin located on the headliner above the b-pillar trim on both the left and right side of
the vehicles needs to be replaced.
CONSEQUENCE: In the event of a vehicle crash, an occupant could be at an increased risk of

injury.
REMEDY: Ford will notify owners and dealers will repair the vehicles free of charge. The safety
recall is expected to begin on or about July 19, 2010. Owners may contact Ford Motor Company at
1-866-436-7332.
NOTES: Ford's recall campaign number is 10C13. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Headliner: Service and Repair
Headliner
Front and rear headliner
NOTE: All pushpin are one time use only.
1. Remove the front overhead console. For additional information, refer to Instrument Cluster /
2. Remove the A-pillar trim panel. For additional information, refer to A-Pillar Trim Panel See: Trim
Panel/Service and Repair/A-Pillar Trim Panel.
3. Remove the front headliner pushpin.
- Remove the 6 rear positioned pushpin.
- Remove the 2 side positioned pushpin.
4. Remove the front headliner by sliding the headliner forward and down.
Rear headliner
5. Remove the LH and RH garment hook screws and the garment hooks.
6. Remove the middle and rear dome lamps.
- Pull the dome lamp housing straight down.
7. Remove the rear headliner pushpin.
8. Remove the headliner.
Front and rear headliner
- Install new pushpins.

Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > Interior Trim - Exploded View
Trim Panel: Service and Repair Interior Trim - Exploded View
Interior Trim - Exploded View
Side Trim

Repair > Interior Trim - Exploded View > Page 5217
Sliding Cargo Door Trim

Rear Cargo Door Trim

Trim Panel: Service and Repair A-Pillar Trim Panel
A-Pillar Trim Panel
1. Remove the door opening weatherstrip that is adjacent to the A-pillar trim panel.
2. Remove the assist handle.
- Remove the 2 assist handle screw covers.
- Remove the 2 assist handle screws. -

3. Remove the A-pillar trim panel.
- Pull inward on the A-pillar trim panel to release the retaining clips.
4. NOTE: To avoid damage to the A-pillar trim panel, remove any retaining clips from the body and
attach them to the A-pillar trim panel before
installing.

Trim Panel: Service and Repair B-Pillar Trim Panel
B-Pillar Trim Panel
Upper and lower
1. Remove the front and rear door opening weatherstrip that is adjacent to the B-pillar trim panel.
2. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain
attached, install a new D-ring cover.
Remove the safety belt D-ring cover.
3. Remove the safety belt bolt and D-ring.
4. Remove the safety belt anchor bolt.
5. Remove the 2 screws that retain the upper B-pillar trim panel to the lower B-pillar trim panel.
Upper LH
6. NOTE: To avoid damage to the B-pillar trim panel, remove any retaining clips from the body and
attach them to the B-pillar trim panel before
installing.
Remove the upper B-pillar trim panel.
- Pull outward on the B-pillar trim panel to release the retaining clips.
Upper RH
7. NOTE: To avoid damage to the B-pillar trim panel, remove any retaining clips from the body and
attach them to the B-pillar trim panel before
installing.
Position the upper B-pillar trim panel aside until the RH lower B-pillar trim panel has been removed.
- Pull outward on the B-pillar trim panel to release the retaining clips.
Lower
8. NOTE: To avoid damage to the scuff plate trim panel, remove any retaining clips from the body
and attach them to the scuff plate trim panel
before installing.
Remove the front scuff plate trim panel screws and lift straight up on the scuff plate trim panel.
9. Reposition the rear scuff plate trim panel.
- Remove the 4 scuff plate trim panel retaining screws.
- Remove the front push-pin.

- Lift the front section of the scuff plate trim panel upward so that the lower B-pillar trim panel can
be removed.
10. Remove the lower B-pillar trim panel.
Upper RH
11. NOTE: The ignition switch must be in the OFF position for at least one minute if disconnecting
the Restraints Control Module (RCM) indicator
electrical connector. Otherwise, a DTC will be set in the RCM memory and must be cleared before
releasing the vehicle.
Turn the ignition to the OFF position and wait one minute.
12. Remove the upper B-pillar trim panel.

- Make sure the key has been in the OFF position for at least one minute and disconnect the Belt
Tension Sensor (BTS) electrical connector (RH side only).
- Position the safety belt through the B-pillar trim panel.
Upper and lower

Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Component
Information > Service and Repair > Instrument Panel - Exploded View
Utility Storage Compartment: Service and Repair Instrument Panel - Exploded View
Instrument Panel - Exploded View
Instrument Panel Electrical Connectors
Instrument Panel Finish Panels

Information > Service and Repair > Instrument Panel - Exploded View > Page 5226
Instrument Panel Fasteners
Utility Storage Compartment: Service and Repair Storage Compartment - Upper
Storage Compartment - Upper
1. NOTICE: When prying on a component, a non-marring tool must be used or damage to the
component may occur.
With a non-marring tool, pry the upper storage compartment upward to release the 11 retaining
clips.

Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair > Removal and Replacement
Door Lock Cylinder: Removal and Replacement
Door Lock Cylinder - Front
Door Lock Cylinder - Front
1. If equipped with power door locks, remove the Central Junction Box (CJB) fuse 163 (20A) to
prevent the Generic Electronic Module (GEM) from
actuating the door locks.
4. Remove the 3 bolts and the front door window glass run.
5. Remove the front door lock cylinder retaining clip.

Service and Repair > Removal and Replacement > Page 5235
6. NOTE: LH door lock cylinder shown.
Release the front door lock cylinder locking pin.
1. Insert the key into the front door lock cylinder and rotate to the unlock position.
2. Using a suitable tool (such as a small flat-blade screwdriver), press in the front door lock cylinder
locking pin and release the key.
7. NOTE: LH door lock cylinder shown.
Remove the front door lock cylinder.
1. Rotate the front door lock cylinder to the lock position.
2. Pull out on the front door lock cylinder.
Door Lock Cylinder - Rear
Door Lock Cylinder - Rear

1. If equipped with power door locks, remove the Central Junction Box (CJB) fuse 163 (20A) to
prevent the Generic Electronic Module (GEM) from
actuating the door locks.
2. Remove the rear door trim panel.
4. Remove the rear door lock cylinder retaining clip.
5. Release the rear door lock cylinder locking pin.
1. Insert the key into the rear door lock cylinder and rotate to the unlock position.
2. Using a suitable tool (such as a pick), press in the rear door lock cylinder locking pin and release
the key.
6. Remove the rear door lock cylinder.
1. Rotate the rear door lock cylinder to the lock position.
2. Pull out on the rear door lock cylinder.


Door Lock Cylinder: Overhaul
Door Lock Cylinder
Disassembly
1. Release the locking tabs on the door lock cylinder return spring guide and slide the door lock
cylinder return spring and guide off the door lock
cylinder barrel.
2. Remove the door lock cylinder barrel retaining clip.

3. NOTE: Place the lock cylinder assembly in a vertical position with the lock cylinder body on top
to keep the tumblers in place during
disassembly.
NOTE: The locking pin falls out during disassembly.
Slide the door lock cylinder body off the door lock cylinder barrel.
4. Note each tumbler identification number and their positions.
Assembly
1. NOTE: The tumblers required can be determined from the vehicle keycode or from the tumblers
identified during disassembly. If necessary, the
factory keycode can be obtained from authorized dealership personnel.
2. NOTE: Make sure that the tumbler indents align with the locking pin slot.
Install the door lock cylinder tumblers and spacers into the door lock cylinder barrel as follows:
3. Apply the multi-purpose grease on the lock cylinder barrel in and around the locking pin slot.
5. Slide the door lock cylinder body onto the door lock cylinder barrel.
6. Place the plastic washer on the end of the lock cylinder barrel.
7. Install the door lock cylinder barrel retaining clip.
8. Install the door lock cylinder return spring and guide, making sure that the door lock cylinder
return spring locates on either side of the the guide.
Ford Workshop Manuals > Body and Frame > Locks > Key > Component Information > Testing and Inspection > Key
Programming Switch State Control
Key: Testing and Inspection Key Programming Switch State Control
Key Programming Switch State Control
NOTE: The spare key programming switch is a programmable switch which provides the capability
to enable/disable the normal customer spare key programming procedure detailed in the Owner's
Literature. It must read ENABLE if more than 2 keys need to be programmed into the Instrument
Cluster (IC). For additional information, refer to Key Programming Using Two Programmed Keys
Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. This
programmable switch is provided as a convenience for rental company fleets or other fleet
purchasers who may not want the spare key programming procedure available to the vehicle
driver.
NOTE: The spare key programming switch state can be viewed with the IC SPAREKEY PID.
NOTE: If the SPAREKEY PID reads ENABLE, up to 8 keys total can be programmed into the IC
using Key Programming Using Two Programmed Keys. If the SPAREKEY PID reads DISABLED,
the Key Programming Using Two Programmed Keys procedure does not function. This switch is
set to ENABLE when the vehicle is built. This PID only affects the Key Programming Using Two
Programmed Keys procedure.
1. Insert a programmed Passive Anti-Theft System (PATS) key (or Integrated Keyhead Transmitter
(IKT)) PATS key (if equipped) into the ignition
lock cylinder and turn the key from the OFF position to the ON position.
3. NOTE: The default setting on delivery of all new vehicles is ENABLED, when viewing the IC
SPAREKEY PID.
From the scan tool menu select: "Customer Spare Key Programming Enable" and follow the IDS
on-screen instructions in order to complete the procedure. -
"Customer Spare Key Programming Enable" - spare key programming procedure is accessible.
- "Customer Spare Key Programming Disable" - spare key programming procedure is not
accessible.
Programming Switch State Control > Page 5245
Key: Testing and Inspection Key Programming Using Diagnostic Equipment
Key Programming Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs keys programmed into the system and
does not have 2 programmed ignition keys available. This procedure is also useful when a
programmed ignition key(s) is lost or the ignition lock cylinder is replaced, and it is desired to erase
key code(s) from the Passive Anti-Theft System (PATS) memory.
NOTE: This procedure erases all programmed ignition keys from the vehicle memory and the
vehicle does not start until 2 keys are programmed to the vehicle. This procedure does not erase
the Integrated Keyhead Transmitter (IKT) identification codes (Transmitter Identification Codes
(TICs)) from the Generic Electronic Module (GEM).
NOTE: A minimum of 2 PATS keys must be programmed into the Instrument Cluster (IC) before
the vehicle starts.
NOTE: Two PATS encoded (contains a transponder) IKT keys (or standard PATS keys) with the
correct mechanical cut must be available to carry out this procedure. One or both of them may be
the customer's original keys. One or both of them may be an IKT key or a standard PATS key. If
the vehicle is not equipped with IKT keys, 2 standard PATS keys are sufficient to complete this
procedure.
NOTE: If additional keys are to be programmed, refer to Key Programming Using Two
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys. If
the remaining keys are with the customer and are not available with the vehicle, instruct the
customer to refer to the Owner's Literature for instructions on programming the remaining keys. In
this case, the IC SPAREKEY PID must be enabled.
1. Turn the PATS key from the OFF position to the ON position.
the Integrated Diagnostic System (IDS)
on-screen instructions to ENTER SECURITY ACCESS. For additional information, refer to

Anti-Theft Security Access See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection/Component Tests and General Diagnostics.
3. From the scan tool menu select: "Ignition Key Code Erase". Follow all IDS screen instructions
until the key erase procedure completes. The scan
tool also instructs to program 2 keys to complete the process.

4. Turn the key to the OFF position and disconnect the scan tool (the key does not need to be
removed from the ignition lock cylinder at this time).
5. Turn the first PATS key in the ignition lock cylinder to the ON position for a minimum of 3
seconds.
6. Turn the first PATS key to the OFF position and remove the key from the ignition lock cylinder.
a minimum of 3 seconds.
8. The vehicle should now start with both PATS ignition keys.
9. If it is desired to program additional key(s) (only up to 8 keys total can be programmed into the
IC), refer to Key Programming Using Two
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys for
each additional key that needs to be programmed.
10. NOTE: Erasing the keys with the scan tool does not erase the RKE transmitter portion of an
IKT PATS key (if equipped) on this vehicle.
Programming the PATS keys using the scan tool or using the Key Programming Using Two
and Inspection/Programming and Relearning/Key Programming Using Two Programmed Keys
procedure does not program the RKE transmitter portion of the IKT PATS key on this vehicle only.
To program the RKE transmitter portion of an IKT PATS key (if equipped), refer to Doors, Hood and
Trunk &/or Locks.
Key: Testing and Inspection Key Programming Using Two Programmed Keys
Key Programming Using Two Programmed Keys
NOTE: This procedure works only if 2 or more programmed ignition keys (they do not have to be
Integrated Keyhead Transmitter (IKT) keys) are present. If 2 programmed Passive Anti-Theft
System (PATS) keys are not available, refer to Key Programming Using Diagnostic Equipment
Inspection/Programming and Relearning/Key Programming Using Diagnostic Equipment.
NOTE: The Instrument Cluster (IC) PID SPAREKEY must be enabled for this procedure to operate.
If this PID is not enabled, refer to Key Programming Switch State Control See: Accessories and
Optional Equipment/Antitheft and Alarm Systems/Testing and Inspection/Programming and
Relearning/Key Programming Switch State Control, in order to enable the customer spare key
programming PID. The PID SPAREKEY is set to ENABLE when the vehicle is built.
NOTE: If the programming procedure is successful, the new key(s) starts the vehicle and the
anti-theft indicator proves-out for approximately 3 seconds. If the programming procedure is not
successful and the new key(s) does not start the engine, leave the key in the ON position for at
least 3 seconds, then turn the key off. Repeat the key programming procedure from Step 1. If the
failure repeats, refer to Anti-Theft in the Diagnosis and Testing to review the DTCs and carry out
the appropriate pinpoint tests. See: Accessories and Optional Equipment/Antitheft and Alarm
Systems/Testing and Inspection
NOTE: A minimum of 2 PATS keys must be programmed into the IC before the vehicle starts.
NOTE: If additional keys are to be programmed, and the remaining keys are with the customer, or
are not available, instruct the customer to refer to the Owner's Literature for instructions on
programming the remaining keys. In this case, the IC PID SPAREKEY must be enabled.
NOTE: If the steps are not carried out as outlined, the programming procedure ends.
NOTE: Ignition keys must have a correct mechanical key cut for the vehicle and must be
PATS-encoded keys (contain a transponder). The key does not have to be an IKT key.
NOTE: A maximum of 8 ignition keys can be programmed to a PATS vehicle, of which up to 4 can
be IKTs (if equipped). If an attempt to program more than 4 IKTs occurs, the additional IKTs do not
have any Remote Keyless Entry (RKE) function capability. The PATS portion of the additional key
functions, but the RKE transmitter function cannot be programmed.
1. Insert a programmed ignition PATS key (can be an IKT or a standard PATS key) into the ignition
lock cylinder and turn the key from the OFF
position to the ON position.
3. Turn the key to the OFF position and remove the first key.
4. Within 10 seconds of turning the key to the OFF position, insert a second programmed PATS
ignition key (can be an IKT or a standard PATS key)
into the ignition lock cylinder and turn the key from the OFF position to the ON position.
6. Turn the key to the OFF position and remove the second key.
7. Within 20 seconds of turning the key to the OFF position, insert the unprogrammed PATS
ignition key (new PATS or IKT key) into the ignition
lock cylinder and turn the key from the OFF position to the ON position. Leave the key in the ON
position for a minimum of 3 seconds.
8. NOTE: The new key now starts the vehicle.
Start the vehicle with the new key.
- If it is an IKT key, follow step 10 below to program the RKE transmitter portion of the IKT key.
9. If additional programmed keys are desired, repeat Steps 1-7.
Key: Testing and Inspection Spare Key Programming - Using Diagnostic Equipment
Spare Key Programming - Using Diagnostic Equipment
NOTE: This procedure is used when a customer needs to have an additional key programmed into
the vehicle without erasing stored key codes, but does not have 2 programmed keys available. This
procedure is also useful when attempting to determine if an ignition key is damaged, as a new key
can be installed without erasing keys or without having 2 programmed keys available.
NOTE: Before programming, the new key must have the correct mechanical cut for the ignition lock
cylinder.
NOTE: If 8 keys are already programmed, this procedure does not allow any more Passive
Anti-Theft System (PATS) keys to be programmed. The number of keys that are programmed into
the PATS can be determined by viewing the Instrument Cluster (IC) PID N_KEYCODE.
1. Turn the unprogrammed PATS key from the OFF position to the ON position.
3. NOTE: Make sure the selection made is "Program additional ignition key". If the "Ignition Key
Code Erase" selection is made, all of the keys are
erased from the system.
From the scan tool menu select: "Program additional ignition key".
5. Start the vehicle with the new PATS key. The vehicle starts with the new PATS key and also with
the original PATS keys.
Key: Testing and Inspection Passive Anti-Theft System (PATS) Parameter Reset
Passive Anti-Theft System (PATS) Parameter Reset
NOTE: A minimum of 2 Passive Anti-Theft System (PATS) keys must be programmed into the
Instrument Cluster (IC) to complete this procedure and allow the vehicle to start.
1. Turn the key from the OFF position to the ON position.
2. From the scan tool, follow the on-screen instructions to ENTER SECURITY ACCESS. For
additional information, refer to Anti-Theft Security
Access See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Testing and
Inspection/Component Tests and General Diagnostics .
3. From the scan tool, select: Parameter Reset and follow the on-screen instructions.
4. NOTE: If the IC or the IC and the PCM were replaced, updated or reconfigured, follow Steps 4-9.
All vehicle keys are erased during the
parameter reset procedure. Verify at least 2 vehicle keys are available prior to carrying out the
PATS parameter reset. If only the PCM was replaced, go to Step 9.
From the scan tool, select: Ignition Key Code Erase and follow the on-screen instructions.
6. Turn the key to the ON position for 6 seconds.
7. Turn the key to the OFF position and remove the key.
6 seconds.
9. Both keys now start the vehicle.
10. If more keys are required to be programmed, refer to Key Programming Using Two
Programmed Keys See: Accessories and Optional

Programming Using Two Programmed Keys.
11. Program the Remote Keyless Entry (RKE) transmitter portion of the Integrated Keyhead
Transmitter (IKT) PATS keys. For additional
information, refer to Doors, Hood and Trunk &/or Locks.

Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming
Keyless Entry Transmitter: Testing and Inspection Remote Keyless Entry (RKE) Transmitter
Programming
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: A maximum of 4 Remote Keyless Entry (RKE) transmitters can be programmed to the
vehicle. Programming must be done at the same time for all the RKE transmitters.
1. NOTE: Make sure the front doors are unlocked and closed, and the ignition is in the OFF
position.
Turn the ignition switch from the OFF to the RUN position 4 times in rapid succession (within 6
seconds), with the fourth turn ending in OFF. If the Generic Electronic Module (GEM) successfully
enters program mode, the Instrument Cluster (IC) sounds a chime.
2. NOTE: If no action is taken within 10 seconds after a transmitter has been programmed, the
programming sequence ends.
Within 10 seconds, press any button on the RKE transmitter to be programmed. The IC chimes to
confirm that each RKE transmitter is programmed. Repeat this step for each RKE transmitter.
3. NOTE: There are NO chimes or any other confirmation from the IC upon exiting programming
mode.
Exiting the programming mode is accomplished if one of the following occurs: -
The ignition transitions to the RUN position.
- 10 seconds have passed since entering programming mode or since the last RKE transmitter was
programmed.
- The maximum number (4) of RKE transmitters have been programmed.
4. Check the operation of the transmitter. If the door locks do not respond for the programmed RKE
transmitter(s), wait several seconds and press the
button again. If the door locks still fail to respond, refer to Handles, Locks, Latches and Entry
Systems. (Make sure that no more than the maximum number of RKE transmitters are attempted
to be programmed.) See: Power Locks/Testing and Inspection
> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5255
Keyless Entry Transmitter: Testing and Inspection Autolock and Auto-Unlock Programming
Autolock and Auto-Unlock Programming
Programming the Autolock Feature
NOTE: This vehicle is not equipped with an Auto-Unlock feature.
NOTE: Make sure that the key is in the OFF position and the doors are closed and unlocked.
NOTE: When programming the autolock feature using the door lock lever method, the following
steps must be carried out within 30 seconds or the procedure will need to be repeated. If the
procedure needs to be repeated, wait 30 seconds between programming sessions.
1. NOTE: If the driver seat belt is not buckled, the Instrument Cluster (IC) will sound the seat belt
warning chime instead of the autolock
programming mode confirmation chime.
Buckle the driver seat belt.
2. Turn the ignition key from the OFF to the RUN position.
4. Turn the ignition key from the RUN to the OFF position.
6. Turn the ignition key to the RUN position. The IC sounds a chime to indicate that programming
mode is entered.
7. To enable/disable the autolock feature, push (lock) and pull (unlock) the driver door lock lever
one time to toggle the state of the autolock feature.
The IC sounds 2 chimes if the autolock has been enabled and 1 chime if the autolock has been
disabled.
8. Turn the ignition key to the OFF position.

> Testing and Inspection > Remote Keyless Entry (RKE) Transmitter Programming > Page 5256
Keyless Entry Transmitter: Testing and Inspection Stepped Unlock Programming
Stepped Unlock Programming
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the
Remote Keyless Entry (RKE) transmitter
simultaneously for 4 seconds. -
The turn signals flash twice to indicate the mode change.
2. Repeat Step 1 to enable/disable the stepped unlocking feature.

Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations > Door Lock Actuator, Left Sliding Door
Power Door Lock Actuator: Locations Door Lock Actuator, Left Sliding Door
> Locations > Door Lock Actuator, Left Sliding Door > Page 5262
Power Door Lock Actuator: Locations Door Lock Actuator, Rear Door
> Diagrams > Door Lock Actuator, Left Sliding Door
Power Door Lock Actuator: Diagrams Door Lock Actuator, Left Sliding Door
> Diagrams > Door Lock Actuator, Left Sliding Door > Page 5265
Power Door Lock Actuator: Diagrams Door Lock Actuator, Right Sliding Door
Power Door Lock Actuator: Diagrams Door Lock Unit, Driver Side Front
Power Door Lock Actuator: Diagrams Door Lock Unit, Passenger Side Front
Power Door Lock Actuator: Diagrams Door Lock Unit, Rear Door
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations

Testing and Inspection > Relays - Micro
Testing and Inspection > Relays - Micro > Page 5276
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
5283
5284
5285
5286
5287

Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >

Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Seat
Backrest - Front
Seat Back: Service and Repair Seat Backrest - Front
Seat Backrest - Front
Backrest Disassembly - View 1
Backrest Disassembly - View 2

Backrest - Front > Page 5302
Backrest Removal - Outboard Side
Backrest Removal - Inboard Side
Disassembly
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow
these instructions may result in the seat side air bag module deploying incorrectly and increase the
risk of serious personal injury or death in a crash.
1. To remove individual parts, only carry out the listed steps as identified in the following table.
Seat Backrest Components - Removal Steps

2. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front
Seat.
3. Remove the head restraint.
- Fully raise the head restraint.
- Insert a suitable tool in the hole to release the RH head restraint guide sleeve and remove the
head restraint.
4. Remove the 2 head restraint guide sleeves.
- Insert a suitable tool on the RH side of each head restraint guide sleeve to release the locking tab
and pry upward to remove.
5. If equipped, remove the spring retainer and armrest.
- Considerable force may be required to separate the armrest.
- The armrest is keyed to the backrest frame. Note position of the armrest keyway for correct
installation.
6. If equipped, remove the adjustable lumbar knob.
- Fully relax the adjustable lumbar.
- Pry to release and remove the lumbar knob.
- Use a suitable tool to release the locking tab behind the handle.
- To avoid scuffing, cover the recliner lever with a suitable shop towel before removing the side
shield.
11. Release all the backrest cover strap clips from under the seat.
Insert a suitable tool to release the locking tab and remove the yellow side air bag module electrical
seat.
13. WARNING: Use care when the seat back frame is removed and when releasing the recliners
from a backrest upright position. The
recliners are spring-loaded, which may cause the recliner upper arms to fold with significant
speed/force. Failure to follow this instruction may result in serious personal injury.
Remove the 4 bolts and seat backrest.
14. Open the backrest cover.
- Release the vertical J-clip and pin-type retainer on each side.
- Release all the remaining backrest cover J-clips.
15. From the front side, release the upper and lower ends of the 2 tensioning rods from the listing
wire in the foam pad.
16. WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or
if the air bag material has been exposed,
install a new seat side air bag module. Never try to repair the seat side air bag module. Failure to
follow these instructions may result in the seat side air bag deploying incorrectly, which increases
WARNING: Check the seat side air bag deployment chute for damage. The deployment chute must
not be repaired. If there is any damage to the deployment chute, a new seat back trim cover and
deployment chute must be installed as a unit. Failure to follow these instructions may result in the
seat side air bag module deploying incorrectly and increase the risk of serious personal injury or
death in a crash.
Remove the side air bag module in the following sequence:
1. Disconnect the electrical connector from the side air bag module.
2. Remove the 2 nuts and separate the side air bag module from the backrest frame.
3. Remove the side air bag module from the deployment chute.
4. Separate the wire harness from the backrest frame and remove. Note the wire harness routing
for correct installation.
17. NOTICE: Use care when removing the hog rings from the foam pad and seat cover. The trim
wire may tear and damage the foam pad.
Invert the backrest cover and remove all the hog rings.
18. Route the deployment chute through the slot in the backrest foam pad and remove the backrest
cover.
19. Remove the backrest foam pad.
20. Remove the lumbar assembly.
- For driver seat, remove the screw and separate the lumbar adjuster from the backrest frame.
- Separate all the lumbar springs from the backrest frame and remove the lumbar assembly.
Assembly
1. To install individual parts, only carry out the listed steps as identified in the following table.
Seat Backrest Components - Installation Steps

2. Install the lumbar assembly.
- Position the lumbar assembly and install all the lumbar springs to the backrest frame.
- For driver seat, install the lumbar adjuster and screw.
3. Install the backrest foam pad to the backrest frame.
4. Position the backrest cover to the backrest and insert the deployment chute through the slot in
the backrest foam pad.
5. Install all the hog rings to the backrest cover and foam pad.
6. WARNING: Before installing the seat side air bag module/deployment chute assembly:
- Inspect the side air bag module and mounting surfaces for any damage or foreign material.
- Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad.
- Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.
WARNING: If the seat side air bag module deployment chute is not correctly positioned, the seat
side air bag may not deploy correctly. Failure to follow this instruction may result in the seat side air
bag deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
Install the side air bag module in the following sequence:
1. Install the side air bag module into the deployment chute and position the studs through the
holes in the chute and backrest frame.
2. Install the 2 side air bag module nuts.

3. Correctly install the wire harness to the backrest frame as noted in removal and connect the
electrical connector to the side air bag module.
7. Install the upper and lower ends of the 2 tensioning rods to the listing wire in the foam pad.
8. Close the backrest cover.
- Fasten the upper and all lower rear J-clips to the backrest frame.
- Install 2 pin-type retainers and fasten the 2 vertical J-clips.
9. Install the seat backrest and 4 bolts.
10. Correctly install the side air bag module wire harness as noted in removal and install the yellow
electrical connector to the seat electrical bulkhead
connector.
11. Fasten all the backrest cover strap clips to the cushion spring assembly under the seat.
- To avoid scuffing, cover the recliner lever with a suitable shop towel before installing the side
shield.
16. If equipped, install the adjustable lumbar knob.
17. If equipped, install the armrest and spring retainer as noted in removal.
18. 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.
Install the 2 head restraint guide sleeves.
- Pull on the head restraint guide sleeves to make sure they are correctly locked to the backrest
frame.
19. Install the head restraint.
- Make sure the head restraint adjusts without excessive effort and locks in place. If binding occurs,
inspect the head restraint guide sleeves for damage and install new as needed.
20. Install the seat. For additional information, refer to Seat - Front See: Service and Repair/Front
Seat.
Seat Back: Service and Repair Seat Backrest - Rear
Seat Backrest - Rear
Backrest Disassembly View
Backrest Removal View

Disassembly
Seat Backrest Components - Removal Steps
2. Push the 2 buttons on the head restraint guide sleeves and remove the head restraint(s).
3. Remove the 2 or 4 head restraint guide sleeves.
- Insert a suitable tool on the RH side of each head restraint guide sleeve to release the locking tab
and pry upward to remove.
- Pull and remove the head restraint guide sleeves.

4. For LH seat, remove the center safety belt anchor and LH safety belt buckle.
- With the seat in the cargo position, remove the bolt, LH safety belt buckle, center safety belt
anchor, washer, spacer and cover. -
Note the spacer shoulder position and safety belt routing for correct installation.
5. Remove the 2 bolts and backrest.
6. For LH seat, remove the screw and safety belt cover.
7. Release the J-clips, unzip and open the backrest cover. Remove the backrest reinforcement
pad.
8. Release all the backrest cover J-clips and remove all the hog rings from the backrest frame.
9. Remove the backrest frame from the backrest foam pad and cover assembly.
10. Remove all the hog rings and backrest cover.
11. For LH seat, remove the bolt and center safety belt retractor.
12. Remove the bolt, backrest latch, spring and retaining nut.
Assembly
To install individual parts, only carry out the listed steps as identified in the following table.
Seat Backrest Components - Installation Steps
2. Install the spring, retaining nut, backrest latch and bolt.
- For correct installation, pretension the spring with a partial turn and make sure the backrest latch
retaining nut is correctly seated to the backrest frame and backrest latch.
3. For LH seat, install the center safety belt retractor and bolt.
4. Position the backrest frame into the foam pad.
- For LH seat, insert the safety belt webbing through the hole in the foam pad.
5. Position the backrest cover to the foam pad and install all the hog rings.
- For LH seat, insert the safety belt webbing through the hole in the backrest cover.
6. Install all the hog rings attaching the backrest cover to the backrest frame, fasten all the backrest
cover J-clips, install the backrest reinforcement
pad, zip and close the backrest cover.
7. For LH seat, install the safety belt cover and screw.
8. Install the backrest assembly and 2 bolts.
- For correct installation, make sure the backrest limiter is positioned into the stop ring on the
cushion frame.
9. For LH seat, install the center safety belt anchor and LH safety belt buckle.
- Correctly position the safety belt buckle, anchor, spacer, washer, cover and bolt as noted in
removal.
10. Install the 2 or 4 head restraint guide sleeves.
- Install the red button guide sleeves on the RH side of the head restraint(s) and black button guide
sleeves on the LH side. Position all the guide sleeves with the release buttons pointed to the LH
side of the vehicle.
- Pull on the head restraint guide sleeves to make sure they are correctly locked to the backrest
frame.
11. Install the head restraint(s).
- Make sure the head restraint adjusts without excessive effort and locks in place. If binding occurs,
inspect the head restraint guide sleeves for damage and install new as needed.
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Seat
Cushion - Front
Seat Cushion: Service and Repair Seat Cushion - Front
Seat Cushion - Front
Driver Seat Cushion

Cushion - Front > Page 5317
Passenger Seat Cushion
Backrest Removal - Outboard Side
Backrest Removal - Inboard Side

Disassembly
All seats
NOTE: Note all wire harness routing for correct installation.
Seat Cushion Components - Removal Steps
2. Remove the seat. For additional information, refer to Seat - Front See: Service and Repair/Front
Seat.

- To avoid scuffing, cover the recliner lever with a suitable shop towel before removing the side
shield.
Insert a suitable tool to release the locking tab and remove the yellow side air bag module electrical
seat.
9. WARNING: Use care when the seat back frame is removed and when releasing the recliners
from a backrest upright position. The
recliners are spring-loaded, which may cause the recliner upper arms to fold with significant
speed/force. Failure to follow this instruction may result in serious personal injury.
Remove the 4 bolts and seat backrest.
10. Release all the J-clips and partially invert the cushion cover up to the hog rings.
11. NOTICE: Use care when removing the hog rings from the foam pad and seat cover. The trim
wire may tear and damage the foam pad.
Remove all hog rings and cushion cover.
Passenger seat
12. NOTE: An Occupant Classification Sensor (OCS) system service kit has the electrical
connector glued to the Occupant Classification System
Module (OCSM). It cannot and should not be disconnected or altered. To remove and install an
OCS system service kit, refer to Occupant Classification Sensor procedure in Restraint Systems.
Remove the cushion foam pad.
13. Remove the OCSM.
- Disconnect the OCSM electrical connector.
- Remove the 2 screws and OCSM.

14. Separate the pressure sensor from the cushion half pan.
- Disconnect the pressure sensor electrical connector.
- Insert a suitable tool between the pressure sensor and bracket to release the locking tab and slide
the pressure sensor off the bracket.
15. Remove the OCS bladder.
- Release the clip and detach the pressure sensor hose from the suspension spring.
- Release the 2 pin-type retainers and remove the OCS bladder from the cushion half pan.
16. Remove the wire harness.
- Detach the seat electrical bulkhead connector from the seat track.
- Insert a suitable tool to release the locking tabs and remove the brown safety belt buckle electrical
connector and yellow side air bag connector from the seat electrical bulkhead connector.
- Detach the harness retainers and remove the wire harness.
Driver seat
17. Remove the cushion foam pad.
18. Remove the seat position sensor.
- Disconnect the electrical connector (at the seat position sensor).

- Release the clip, slide and remove the seat position sensor.
19. Insert a suitable tool to release the locking tab and remove the red electrical connector from the
seat electrical bulkhead connector. Separate the
wire harness from under the seat.
All seats

Remove the safety belt buckle.
- Insert a suitable tool to release the locking tab and remove the brown safety belt buckle electrical
seat.
- Remove the bolt and safety belt buckle.
21. Remove the cushion spring assembly.
- Release the retainers from the rear of the seat track and separate from the cushion half pan.
- Release all remaining wire harness retainers attached to the cushion spring assembly.
22. Remove the 4 screws and cushion half pan.
Assembly
All seats
NOTE: Make sure all seat wire harnesses are correctly routed and attached as noted in removal.
1. To install individual parts, only carry out the listed steps as identified in the following table.
Seat Cushion Components - Installation Steps

2. Install the cushion half pan and 4 screws to the seat track.
3. Install the cushion spring assembly to the cushion half pan and seat track.
Driver seat
4. Install the seat position sensor and connect the electrical connector.
- Make sure the clip is locked for correct installation.
- Correctly install the wire harness as noted in removal and install the red electrical connector to the
5. Install the foam pad.
Passenger seat
6. NOTICE: While positioning the seat cushion frame and Occupant Classification Sensor (OCS)
system assembly, be careful not to damage
any of the components. Failure to do so may result in component failure.
Install the OCS bladder.
- Route the pressure sensor and hose through the correct opening in the suspension spring.
engaged. -
Check the pressure sensor bracket for secure mounting. If the bracket is loose, install a new rivet
- Connect the pressure sensor and OCSM electrical connectors.

All seats
12. Fasten all the cushion cover J-clips.
13. Install the safety belt buckle and bolt.
- Install the wire harness and install the brown electrical connector to the seat electrical bulkhead
connector.
14. Install the seat backrest and 4 bolts.
15. Install the side air bag module, wire harness and install the yellow electrical connector to the
16. Fasten all backrest cover strap clips to the cushion spring assembly under the seat.
- To avoid scuffing, cover the recliner lever with a suitable shop towel before installing the side
shield.
21. Install the seat. If a passenger seat has been serviced, do not prove out the SRS at this time.
For additional information, refer to Seat - Front
See: Service and Repair/Front Seat.
Passenger seat
death in a crash.
less than 18 volts.

Seat Cushion: Service and Repair Seat Cushion - Rear
Seat Cushion - Rear
Cushion Disassembly View

Backrest Removal View

Disassembly
Seat Cushion Components - Removal Steps
2. Remove the seat. For additional information, refer to Seat - Rear See: Service and Repair/Rear
Seat.
3. For LH seat, remove the center safety belt anchor and LH safety belt buckle.
- Remove the bolt, LH safety belt buckle, center safety belt anchor, washer, spacer and cover. -
Note the spacer shoulder position and safety belt routing for correct installation.
4. Remove the 2 bolts and backrest.
5. Remove the screw and cushion latch release handle.
6. Remove the 3 screws and strut cover.
7. Release all the J-clips from the cushion frame and invert the cushion cover.
- Note routing of the backrest release strap for correct installation.
8. Remove all the hog rings and cushion cover.
9. Remove the cushion foam pad.
10. Remove the bolt, safety belt buckle (RH or center), washer, spacer and cover.
- Note the spacer shoulder position and safety belt routing for correct installation.
11. Remove the bolt and child safety seat tether anchor.
12. Remove the 4 screws and pedestal cover(s).
Assembly
To install individual parts, only carry out the listed steps as identified in the following table.
Seat Cushion Components - Installation Steps
2. Install the pedestal cover(s) and 4 screws.
3. Install the child safety seat tether anchor and bolt.
4. Install the safety belt buckle (RH or center), washer, spacer, cover and bolt.
- Correctly position the safety belt buckle, spacer, washer, cover and bolt as noted in removal.
5. Install the cushion foam pad.
6. Position the cushion cover to the foam pad and install all the hog rings.
- Route the cushion cover straps through the child safety seat anchor wires.
7. Fasten all the cushion cover J-clips to the cushion frame.
- Correctly route the backrest release strap as noted in removal.

8. Install the strut cover and 3 screws.
9. Install the cushion latch release handle and screw.
10. Install the backrest assembly and 2 bolts.
- For correct installation, make sure the backrest limiter is positioned into the stop ring on the
cushion frame.
11. For LH seat, install the center safety belt anchor and LH safety belt buckle.
- Correctly position the safety belt buckle, anchor, spacer, washer, cover and bolt as noted in
removal.
12. Install the seat. For additional information, refer to Seat - Rear See: Service and Repair/Rear
Seat.
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Position Switch >
Component Information > Locations > Sliding Door Contact Switch, Right
Door Position Switch: Locations Sliding Door Contact Switch, Right
Door Position Switch: Locations Sliding Door Contact Switch, Left
Door Position Switch: Locations Sliding Door Ajar Switch, Left
Door Position Switch: Locations Sliding Door Ajar Switch, Right
Component Information > Diagrams > Sliding Door Contact Switch, Right
Door Position Switch: Diagrams Sliding Door Contact Switch, Right
Door Position Switch: Diagrams Sliding Door Contact Switch, Left
Door Position Switch: Diagrams Sliding Door Ajar Switch, Left
Door Position Switch: Diagrams Sliding Door Ajar Switch, Right
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >

Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation
Sound Proofing / Insulation: Description and Operation Insulation
Insulation
Body insulation is comprised of urethane, Polyvinyl Chloride (PVC), foam and recycled felt.
Insulation is used as a sound deadener to reduce exterior road and powertrain noises from the
interior of the vehicle. Mastic insulators are also used as insulation. For information on the location
of the mastic insulators, refer to Sound Deadeners and Insulators. Insulation is installed:
- above and below the instrument panel.
- at the cowl side panels.
- over the front and rear floor pan areas.
- over the luggage compartment floor.

Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation > Insulation > Page 5359
Sound Proofing / Insulation: Description and Operation Sound Deadeners and Insulators
Sound Deadeners and Insulators
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.
NOTICE: Mastic is made of a combustible material and should be removed prior to carrying out
welding procedures to the area. Heat zones from welding near the mastic may cause the mastic
material to burn.
NOTICE: Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products may be wax based and loss of adhesion may occur.
NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and
insulators should be installed with the correct service replacement component.
NOTE: The following illustrations serve as a reference to indicate mastic patch (butyl pad)
locations. Additional insulators and sound deadeners are used beyond those indicated in the
illustration.
1. Whenever replacement of an existing mastic insulator is carried out, the surface must be
thoroughly cleaned to make sure correct adhesion will
occur. The surface should be 10°C (50°F) or greater before applying the mastic. The use of a heat
gun to warm the metal surface will aid in adhesion.
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Technical
Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Service Bulletins > Customer Interest for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues >
Page 5370
Page 5371
(Figure 5)
Page 5372
(Figure 7)
hinge.

Page 5373
under the hood.
Page 5374
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Page 5375
Disclaimer
Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > 11-3-10 > Mar > 11 > Body - Various Water
Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Service Bulletins > All Technical Service Bulletins for Cowl Moulding / Trim: > Page 5387
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Cowl Panel Grille
Systems.


All vehicles

Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Weatherstrip > System Information > Technical
Service Bulletins > Customer Interest for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Service Bulletins > Customer Interest for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues >
Page 5410
Page 5411
(Figure 5)
Page 5412
(Figure 7)
hinge.

Page 5413
under the hood.
Page 5414
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Page 5415
Disclaimer
Service Bulletins > All Technical Service Bulletins for Cowl Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various Water Leak
Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Issues > Page 5421
Issues > Page 5422
(Figure 5)
Issues > Page 5423
(Figure 7)
hinge.

Issues > Page 5424
under the hood.
Issues > Page 5425
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Issues > Page 5426
Disclaimer
Service Bulletins > All Technical Service Bulletins for Cowl Weatherstrip: > Page 5427
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Weatherstrip > Cowl Weatherstrip > System Information > Technical Service
Bulletins > Customer Interest: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Bulletins > Customer Interest: > 11-3-10 > Mar > 11 > Body - Various Water Leak Issues > Page 5449
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

> Page 5460
> Page 5461
(Figure 5)
> Page 5462
(Figure 7)
hinge.

> Page 5463
under the hood.
> Page 5464
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
> Page 5465
Disclaimer
Bulletins > All Other Service Bulletins for Cowl Weatherstrip: > 10-11-4 > Jun > 10 > A/C - Blower Motor Runs
Wiring Harness HVAC: All Technical Service Bulletins A/C - Blower Motor Runs
TSB 10-11-4
06/21/10

SERVICE PROCEDURE
proceed to Step 3.

(Figure 1)
Cell 5.
(Figure 4)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > All Other Service Bulletins for Cowl Weatherstrip: > 09-19-6 > Oct > 09 > A/C - Blower Motor Won't Turn
OFF/One Speed Inop.
Wiring Harness HVAC: All Technical Service Bulletins A/C - Blower Motor Won't Turn OFF/One
Speed Inop.
TSB 09-19-6
10/05/09

SPEED
SERVICE PROCEDURE
(Figure 1)
5.
(Figures 2 and 3)
(Figure 4)
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14401 30
Disclaimer
Bulletins > All Other Service Bulletins for Cowl Weatherstrip: > Page 5479
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 11-2-18 > Feb > 11 > Body - Front Door
Upper Weatherstrip Loose/Falling Off
Front Door Weatherstrip: Customer Interest Body - Front Door Upper Weatherstrip Loose/Falling
Off
TSB 11-2-18
02/28/11
SERVICE PROCEDURE

NOTE
°F) CONTINUOUSLY.
complete adhesion

Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 11-2-18 > Feb > 11 > Body - Front Door
Upper Weatherstrip Loose/Falling Off > Page 5500
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
110218B 2010-2011 Transit 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 11-2-18 > Feb > 11 > Body -
Front Door Upper Weatherstrip Loose/Falling Off
Loose/Falling Off
TSB 11-2-18
02/28/11
SERVICE PROCEDURE

NOTE
°F) CONTINUOUSLY.
complete adhesion

Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 11-2-18 > Feb > 11 > Body -
Front Door Upper Weatherstrip Loose/Falling Off > Page 5506
Parts Block

110218A 2010-2011 Transit 0.4 Hr.
110218B 2010-2011 Transit 0.5 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1551822 07
Disclaimer
Ford Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door

Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 5511
straight up.


Ford Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information >
Technical Service Bulletins > Customer Interest for Trunk / Liftgate Weatherstrip: > 11-3-10 > Mar > 11 > Body - Various
Water Leak Issues
Trunk / Liftgate Weatherstrip: Customer Interest Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

Water Leak Issues > Page 5521
(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Weatherstrip: > 11-3-10 > Mar > 11 > Body -
Various Water Leak Issues
Trunk / Liftgate Weatherstrip: All Technical Service Bulletins Body - Various Water Leak Issues
TSB 11-3-10
03/15/11
VARIOUS WATER LEAKS
vehicle.
SERVICE PROCEDURE

(Figure 5)
(Figure 7)
hinge.

under the hood.
Of This Article)
110310F 2010-2011 Transit 0.9 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
1625315 07
Disclaimer
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page
5542
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page
5543
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
follows: -
Typical BPP Switch

Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
strategy.
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Description and
Operation

Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair

Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
follows: -
Typical BPP Switch

strategy.
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >

Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component
Air Bag Deactivation Indicator: Diagrams
Air Bag Deactivation Indicator: Service and Repair
Passenger Air Bag Deactivation (PAD) Indicator
Turn the key off and wait at least one minute.
2. NOTICE: Use a non-marring tool to pry on the component. Failure to do so will cause damage to
the component.
Pry upward on the upper storage compartment to release the 11 retaining clips.
3. Disengage the locking tabs and remove the PAD indicator.

4. Disconnect the PAD indicator electrical connector.
illuminate continuously for approximately 6 seconds and then turn off. If a SRS fault is present, the
occur until approximately 30 seconds after the ignition has been turned from OFF to the ON
warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5
beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be
diagnosed and repaired. Clear all continuous DTCs from the RCM and Occupant Classification
System Module (OCSM).
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Cigarette Lighter: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Cigarette Lighter: Connector Views

Cigarette Lighter: Electrical Diagrams
44-1
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Supplemental Restraint System (SRS) Depowering
and Repowering

to Battery.
and Repowering > Page 5604
Deactivation
latches.
impact sensor(s).
to Battery.

connectors.

Reactivation
refer to Battery.
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Door Ajar Switch, Left Front
Locations > Door Ajar Switch, Left Front > Page 5615
Locations > Door Ajar Switch, Left Front > Page 5616
Diagrams > Door Ajar Switch, Left Front

Diagrams > Door Ajar Switch, Left Front > Page 5619

Diagrams > Door Ajar Switch, Left Front > Page 5620

Diagrams > Page 5621

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator >
Fuel Filler Cap Warning Indicator: Description and Operation
Check Fuel Cap Indicator
The check fuel cap indicator is a communications network message sent by the PCM. The PCM
sends the message to illuminate the lamp when the strategy determines there is a concern in the
EVAP system due to the fuel filler cap or capless fuel tank filler pipe not being sealed correctly.
This is detected by the inability to pull vacuum in the fuel tank after a fueling event.
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Description and Operation > Fuel Pump (FP) Module

Information > Description and Operation > Fuel Pump (FP) Module > Page 5632
tank fill levels.

Fuel Pump Module
personal injury.
ring.
arm.

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
and Repowering

to Battery.
Deactivation
latches.
impact sensor(s).
to Battery.

connectors.

Reactivation
refer to Battery.
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
concern is present.
- For all MIL concerns, go to Symptom Charts. See: Powertrain Management/Computers and
Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures
DTC P1000 is set.

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch

Information > Service and Repair > Oil Filter, Oil Filter Adapter, Oil Cooler and Engine Oil Pressure (EOP) Switch > Page
5658

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Parking Assist Warning Indicator: Diagrams

Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Seat Belt Reminder Lamp: Service and Repair
Belt-Minder(R) Deactivating/Activating
Preparation
NOTE: The driver and front passenger Belt-Minder(R) are deactivated/activated through the driver
safety belt buckle.
NOTE: The Belt-Minder(R) can also be deactivated/activated using the scan tool.
1. Place the transmission selector lever in PARK.
3. Unbuckle the driver and front passenger safety belts.
Deactivating/Activating
1. Turn the ignition switch to the RUN position (do not start the engine).
2. Wait approximately 1 minute until the safety belt warning indicator turns off.
3. NOTE: Step 3 must be completed within 50 seconds after the safety belt warning indicator turns
off.
NOTE: Buckle and unbuckle the safety belt at a moderate rate. If the safety belt
buckle/unbuckle/buckle sequence is carried out too fast, the Restraints Control Module (RCM) can
fail to recognize one of the sequences and the procedure must be repeated.
To disable or enable the Belt-Minder(R) feature, buckle then unbuckle the driver safety belt 9 times,
ending in the unbuckled state.
- This disables the Belt-Minder(R) feature for both driver and passenger seating positions, if it is
currently enabled. As confirmation, the safety belt warning indicator flashes 4 times per second for
3 seconds.
- This enables the Belt-Minder(R) feature for both driver and passenger seating positions, if it is
currently disabled. As confirmation, the safety belt warning indicator flashes 4 times per second for
3 seconds, followed by 3 seconds with the light off, then followed by the safety belt warning
indicator flashing 4 times per second for 3 seconds again.
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair

Door Switch > Component Information > Locations > Door Ajar Switch, Left Front
Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 5678
Door Switch > Component Information > Locations > Door Ajar Switch, Left Front > Page 5679
Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front

Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 5682

Door Switch > Component Information > Diagrams > Door Ajar Switch, Left Front > Page 5683

Door Switch > Component Information > Diagrams > Page 5684

Fuel Gauge Sender > Component Information > Locations
Fuel Gauge Sender > Component Information > Locations > Page 5688
Fuel Gauge Sender > Component Information > Locations > Page 5689
Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module

Fuel Gauge Sender > Component Information > Description and Operation > Fuel Pump (FP) Module > Page 5692
tank fill levels.
Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View

Fuel Gauge Sender > Component Information > Service and Repair > Fuel Tank and Filler Pipe - Exploded View > Page
5695
5696
5697
Fuel Pump Module
personal injury.
ring.
arm.
5698

Parking Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch > Component Information > Locations > Page 5702
Parking Brake Warning Switch > Component Information > Locations > Page 5703
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure
Module > Component Information > Locations

Removal
damage may result.
to Information Bus.
Installation

Readiness Codes.
Sensor > Component Information > Testing and Inspection > Tire Pressure Monitoring System (TPMS) Sensor Training
Training
illuminate.
position.
position.
successfully.
vehicle doors open.

Page 5718
repeated.
Page 5719
Activation
stem.
vehicle doors open.
Procedures
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T >
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Testing
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
and Instructions > Page 5742
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Brake Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Brake Lamp: Electrical Diagrams
90-1
90-2
90-3
90-4
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Brake Lamp: Initial Inspection and Diagnostic Overview

Stoplamps
Stoplamps
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If the concern is not visually evident, verify the symptom. GO to Symptom Chart. See: Symptom
Stoplamps
When the brake pedal is applied with the ignition ON, the stoplamp switch routes voltage to all the
stoplamps and the PCM.
Inspection and Diagnostic Overview > Page 5767
Brake Lamp: Symptom Related Diagnostic Procedures
Stoplamps
Symptom Chart
Brake Lamp: Pinpoint Tests
Pinpoint Test H: One Or More Stoplamps Are Inoperative
Stoplamps
Pinpoint Tests
Pinpoint Test H: One Or More Stoplamps Are Inoperative
Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector
Normal Operation
The Central Junction Box (CJB) fuse 142 (15A) supplies voltage to the stoplamp switch when the
ignition is ON. When the brake pedal is applied, the stoplamp switch routes voltage to the
stoplamps.
- Fuse
- Stoplamp switch
- Rear lamp jumper harness
- High mounted stoplamp
PINPOINT TEST H: ONE OR MORE STOPLAMPS ARE INOPERATIVE
------------------------------------------------- H1 DETERMINE THE INOPERATIVE STOPLAMP
- Ignition ON.
- Apply the brake pedal and observe the stoplamps.
- Are all the stoplamps inoperative?
Yes
VERIFY the CJB fuse 142 (15A) is OK. If OK, GO to H2.
If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. See:
No
If the high mounted stoplamp is inoperative, GO to H4.
If a rear stoplamp is inoperative, GO to H6.
------------------------------------------------- H2 CHECK FOR VOLTAGE TO THE STOPLAMP SWITCH

- Disconnect: Stoplamp Switch C278.
- Measure the voltage between the stoplamp switch C278-1, circuit 15-LG23 (GN/WH), harness
side and ground.
Yes
GO to H3.
No
REPAIR circuit 15-LG23 (GN/WH) for an open. TEST the system for normal operation.
------------------------------------------------- H3 BYPASS THE STOPLAMP SWITCH
- Connect a fused jumper wire between the stoplamp switch C278-1, circuit 15-LG23 (GN/WH),
harness side and the stoplamp switch C278-4, circuit 15S-LG23 (GN/WH), harness side.
- Do the stoplamps illuminate?
Yes
REMOVE the jumper wire. INSTALL a new stoplamp switch. REFER to Stoplamp Switch See:
Brake Light Switch/Service and Repair. TEST the system for normal operation.
No
REMOVE the jumper wire. REPAIR stoplamp switch output circuit for an open. TEST the system
for normal operation.
------------------------------------------------- H4 CHECK FOR VOLTAGE TO THE HIGH MOUNTED

STOPLAMP
- Disconnect: High Mounted Stoplamp C904.
- While applying the brake pedal, measure the voltage between the high mounted stoplamp
C904-1, circuit 15S-LG6 (GN/YE), harness side and ground.
Yes
GO to H5.
No
REPAIR circuit 15S-LG6 (GN/YE) for an open. TEST the system for normal operation.
------------------------------------------------- H5 CHECK FOR VOLTAGE TO THE HIGH MOUNTED

STOPLAMP USING THE CONNECTOR GROUND
- While applying the brake pedal, measure the voltage between the high mounted stoplamp
C904-1, circuit 15S-LG6 (GN/YE), harness side and the high mounted stoplamp C904-2, circuit
31-LG6 (BK), harness side.
Yes
INSTALL a new high mounted stoplamp. REFER to High Mounted Stoplamp See: Center Mounted
Brake Lamp/Service and Repair. TEST the system for normal operation.
No
REPAIR circuit 31-LG6 (BK) for an open. TEST the system for normal operation.
------------------------------------------------- H6 CHECK FOR VOLTAGE TO THE REAR LAMP
- Disconnect: Inoperative Rear Lamp.
- While applying the brake pedal, measure the voltage between the LH rear lamp C414-6, circuit
15S-LG14 (GN/RD), harness side and ground; or between the RH rear lamp C417-6, circuit
15S-LG21 (GN/BK), harness side and ground.
Yes
GO to H7.
No
REPAIR circuit 15S-LG14 (GN/RD) (LH rear lamp) or circuit 15S-LG21 (GN/BK) (RH rear lamp) for
an open. TEST the system for normal operation.
------------------------------------------------- H7 CHECK FOR VOLTAGE TO THE REAR LAMP USING

THE CONNECTOR GROUND
- While applying the brake pedal, measure the voltage between the LH rear lamp C414-6, circuit
15S-LG14 (GN/RD), harness side and the LH rear lamp C414-5, circuit 31-LF23 (BK), harness
side; or between the RH rear lamp C417-6, circuit 15S-LG21 (GN/BK), harness side and the RH
rear lamp C417-5, circuit 31-LF24 (BK), harness side.
Yes
REPAIR or INSTALL a new rear lamp jumper harness. TEST the system for normal operation.
No
REPAIR circuit 31-LF23 (BK) (LH rear lamp) or circuit 31-LF24 (BK) (RH rear lamp) for an open.
TEST the system for normal operation.
-------------------------------------------------
Pinpoint Test I: The Stoplamps Are On Continuously
Stoplamps
Pinpoint Tests
Pinpoint Test I: The Stoplamps Are On Continuously
Refer to Wiring Diagram Set 90, Turn Signal/Stop/Hazard Lamps for schematic and connector
Normal Operation
When the brake pedal is applied, the stoplamp switch routes voltage to the stoplamps and the
PCM.
- Stoplamp switch
- PCM
PINPOINT TEST I: THE STOPLAMPS ARE ON CONTINUOUSLY
------------------------------------------------- I1 CHECK THE STOPLAMP SWITCH
- Disconnect: Stoplamp Switch C278.
- Do the stoplamps continue to illuminate?
Yes
GO to I2.
No
INSTALL a new stoplamp switch. REFER to Stoplamp Switch See: Brake Light Switch/Service and
Repair. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- I2 CHECK THE PCM
- Do the stoplamps continue to illuminate?
Yes
REPAIR the stoplamp switch output circuit for a short to voltage. TEST the system for normal
operation.
No
GO to I3.
------------------------------------------------- I3 CHECK FOR CORRECT PCM OPERATION
- Check for: -
corrosion
- damaged pins
- pushed-out pins
Yes
INSTALL a new PCM. REFER to Computers and Control Systems. TEST the system for normal
operation.
No
corroded connector.
-------------------------------------------------
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
5773
Brake Lamp: Service and Repair
Rear Lamp Assembly
NOTE: The rear door is shown removed for clarity.

1. Remove the 2 fasteners and the rear lamp assembly.
2. If necessary, remove the bulb from the bulb holder.

Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5777
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 5778
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation
> Brake Pedal Position (BPP) Switch
follows: -
Typical BPP Switch

> Brake Pedal Position (BPP) Switch > Page 5781
strategy.
> Page 5782
Stoplamp Switch

Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams
Center Mounted Brake Lamp: Diagrams

Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page
5786
Center Mounted Brake Lamp: Service and Repair
High Mounted Stoplamp
1. If equipped with a rear headliner, remove the pin-type retainers and lower the headliner to
access the high mounted stoplamp nuts and electrical
connector.
2. Disconnect the high mounted stoplamp electrical connector.
3. Remove the 2 nuts and the high mounted stoplamp.

Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information >
Locations

Testing and Inspection > Relays - Micro
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair

Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair
Dome Lamp: Service and Repair
Interior Lamp
NOTICE: When prying on the front interior lamp, a non-marring tool must be used or damage to the
front interior lamp or overhead console can occur.
1. With a non-marring tool (such as a plastic scraper), pry the front interior lamp downward to
release it from the overhead console.

Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Door Ajar Switch, Left
Front
Front > Page 5815
Front > Page 5816
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Door Ajar Switch, Left
Front

Front > Page 5819

Front > Page 5820

Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Page 5821

Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram
Fog/Driving Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Fog/Driving Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Fog/Driving Lamp: Electrical Diagrams
86-1
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Testing and Inspection >
Initial Inspection and Diagnostic Overview
Fog/Driving Lamp: Initial Inspection and Diagnostic Overview
Fog Lamps
Fog Lamps
The Central Junction Box (CJB) provides voltage at all times to the headlamp switch for the rear
fog lamp functionality. When the headlamp switch is placed in the HEADLAMPS ON position (the
ignition switch can be in any position) and the fog lamp switch is engaged, the headlamp switch
provides voltage to the rear fog lamps.
Fog Lamps
2. Visually inspect for obvious signs of electrical damage.
Initial Inspection and Diagnostic Overview > Page 5848
Fog/Driving Lamp: Symptom Related Diagnostic Procedures
Fog Lamps
Symptom Chart
Fog/Driving Lamp: Pinpoint Tests
Pinpoint Test P: Both Rear Fog Lamps Are Inoperative
Fog Lamps
Pinpoint Tests
Pinpoint Test P: Both Rear Fog Lamps Are Inoperative
Refer to Wiring Diagram Set 86, Fog Lamps for schematic and connector information. See:
Normal Operation
The Central Junction Box (CJB) fuse 141 (10A) provides voltage at all times to the headlamp
switch. When the headlamp switch is placed in the HEADLAMPS ON position and the fog lamp
switch is engaged, the headlamp switch provides voltage to the rear fog lamps.
- Fuse
- Headlamp switch
PINPOINT TEST P: BOTH REAR FOG LAMPS ARE INOPERATIVE
------------------------------------------------- P1 CHECK FOR VOLTAGE TO THE HEADLAMP SWITCH
- Ignition OFF.
- Disconnect: Headlamp Switch C205.
- Measure the voltage between the headlamp switch C205-7, circuit 15-LD16 (GN/RD), harness
side and ground.

Yes
GO to P2.
No
VERIFY the CJB fuse 141 (10A) is OK. If OK, REPAIR circuit 15-LD16 (GN/RD) for an open. TEST
the system for normal operation.
If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short. See:
------------------------------------------------- P2 BYPASS THE HEADLAMP SWITCH

- Connect a fuse jumper wire between the headlamp switch C205-7, circuit 15-LD16 (GN/RD),
harness side and the headlamp switch C205-2, circuit 15S-LD6 (GN/YE), harness side.
- Do the rear fog lamps illuminate?
Yes
INSTALL a new headlamp switch. REFER to Headlamp Switch See: Headlamp/Headlamp

Switch/Service and Repair. TEST the system for normal operation.
No
REPAIR circuit 15S-LD6 (GN/YE) for an open. TEST the system for normal operation.
-------------------------------------------------
Pinpoint Test Q: An Individual Rear Fog Lamp Is Inoperative
Fog Lamps
Pinpoint Tests
Pinpoint Test Q: An Individual Rear Fog Lamp Is Inoperative
Normal Operation
When the headlamp switch is placed in the HEADLAMPS ON position and the fog lamp switch is
engaged, the headlamp switch provides voltage to the rear fog lamps.
PINPOINT TEST Q: AN INDIVIDUAL REAR FOG LAMP IS INOPERATIVE

------------------------------------------------- Q1 CHECK FOR VOLTAGE TO THE INOPERATIVE LAMP
- Ignition OFF.
- Disconnect: Inoperative Rear Fog Lamp.
- Ignition ON.
- Place the headlamp switch in the HEADLAMPS ON position and engage the fog lamp switch.
- Measure the voltage between the LH rear lamp C414-1, circuit 15S-LD6 (GN/YE), harness side
and ground; or between the RH rear lamp C417-1, circuit 15S-LD12 (GN/YE), harness side and
ground.
Yes
GO to Q2.
No
REPAIR circuit 15S-LD6 (GN/YE) (LH rear fog lamp) or circuit 15S-LD12 (GN/YE) (RH rear fog
lamp) for an open. TEST the system for normal operation.
------------------------------------------------- Q2 CHECK FOR VOLTAGE TO THE INOPERATIVE LAMP

USING THE CONNECTOR GROUND
- Measure the voltage between the LH rear lamp C414-1, circuit 15S-LD6 (GN/YE), harness side
and the LH rear lamp C414-5, circuit 31-LF23 (BK), harness side; or between the RH rear lamp
C417-1, circuit 15S-LD12 (GN/YE), harness side and the RH rear lamp C417-5, circuit 31-LF24
(BK), harness side.
Yes
REPAIR or INSTALL a new rear lamp jumper harness. TEST the system for normal operation.
No
REPAIR the rear lamp ground circuit in question for an open. TEST the system for normal
operation.
-------------------------------------------------
Pinpoint Test R: The Rear Fog Lamps Are On Continuously
Fog Lamps
Pinpoint Tests
Pinpoint Test R: The Rear Fog Lamps Are On Continuously
Normal Operation
When the headlamp switch is placed in the HEADLAMPS ON position and the fog lamp switch is
engaged, the headlamp switch provides voltage to the rear fog lamps. Voltage is also routed to the
Generic Electronic Module (GEM) to indicate the rear fog lamps are on (rear fog lamps on
indicator).
- DTC B2509 (Rear Fog Lamp Switch Circuit Failure) - an on-demand DTC that sets when the
GEM detects a short to voltage from the fog lamps voltage supply circuit.
- Headlamp switch
- GEM
PINPOINT TEST R: THE REAR FOG LAMPS ARE ON CONTINUOUSLY
------------------------------------------------- R1 CHECK THE HEADLAMP SWITCH
- Ignition OFF.
- Ignition ON.
- Do the rear fog lamps continue to illuminate?
Yes
GO to R2.
No

Switch/Service and Repair. CLEAR the DTCs. REPEAT the self-test.
------------------------------------------------- R2 CHECK THE GEM
- Ignition OFF.
- Ignition ON.
- Do the rear fog lamps continue to illuminate?
Yes
REPAIR the rear fog lamps voltage supply circuit for a short to voltage. TEST the system for
normal operation.
No
GO to R3.
------------------------------------------------- R3 CHECK FOR CORRECT GEM OPERATION
- Ignition OFF.

- Check for: -
corrosion
- damaged pins
- pushed-out pins
Yes
INSTALL a new GEM. REFER to Body Control Systems. TEST the system for normal operation.
No
corroded connector. CLEAR any DTCs. REPEAT the self-test.
-------------------------------------------------
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
instrument panel.

Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
Headlamp Bulb
NOTE: The engine air cleaner is shown removed for clarity.
WARNING: The bulb contains gas under pressure. The bulb may shatter if the glass envelope is
scratched or if the bulb is dropped. Handle the bulb only by its base. Avoid touching the glass
envelope. Failure to follow these instructions may result in personal injury.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a new bulb
is installed. Removing the bulb for an extended period of time may affect headlamp bulb
performance. Contaminants may enter the headlamp where they can settle on the lens and
reflector. Never turn on the headlamps with the bulb removed.
NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position.
1. Remove the headlamp bulb access cover.
2. Disconnect the headlamp bulb electrical connector.
3. Rotate the headlamp bulb approximately one-eighth turn counterclockwise and remove it from
the headlamp assembly.

Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Low
Beam Relay
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Low
Beam Relay > Page 5878
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Testing and
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations >
Page 5887
Page 5888
Page 5889
Page 5890
Page 5891
Headlamp Switch

Ford Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Locations

Ford Workshop Manuals > Lighting and Horns > Headlamp > Low Beam Relay > Component Information > Testing and
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
License Plate Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
License Plate Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
License Plate Lamp: Connector Views
License Plate Lamp, Left

License Plate Lamp, Right

License Plate Lamp: Electrical Diagrams
92-1
92-2
92-3
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 5934
License Plate Lamp: Service and Repair
License Plate Lamp
NOTE: The license plate lamp lens and bulb can be removed without removing the assembly.
1. Remove the pin-type retainers and the rear door trim panel.
2. Disconnect the license plate lamp electrical connector.
3. Release the tabs and remove the license plate lamp from the rear door.

Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Marker Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Marker Lamp: Connector Views
Marker Lamp, Left Rear
Marker Lamp, Right Rear
Side Lamp, Left Front

Side Lamp, Right Front
Marker Lamp: Electrical Diagrams
92-1
92-2
92-3
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Page 5963
Marker Lamp: Service and Repair
Side Marker Lamp
NOTE: Rear side marker lamp shown, front similar.
1. Using a thin flat-bladed tool, separate the lamp from the bumper cover.
2. Separate the bulb holder from the side marker lamp.
- If necessary, remove the bulb from the bulb holder.

Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Parking Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Parking Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Parking Lamp: Electrical Diagrams
92-1
92-2
92-3
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Parking Lamp: Initial Inspection and Diagnostic Overview
Parking, Rear and License Plate Lamps

2. Visually inspect for obvious signs of mechanical or electrical damage.
The headlamp switch is provided voltage at all times from the Central Junction Box (CJB). When
the headlamp switch is placed in the HEADLAMPS ON position, voltage is routed to the GEM (as
an input), and through the CJB fuses to the parking lamps.
Parking Lamp: Symptom Related Diagnostic Procedures
Symptom Chart
Parking Lamp: Pinpoint Tests
Pinpoint Test N: One Or More Parking, Rear Or License Plate Lamps Is Inoperative
Pinpoint Tests
Pinpoint Test N: One Or More Parking, Rear or License Plate Lamps Is Inoperative
Refer to Wiring Diagram Set 92, Parking, Rear and License Lamps for schematic and connector
Normal Operation
The Central Junction Box (CJB) fuse 132 (10A) provides voltage at all times to the headlamp
switch. When the headlamp switch is placed in the PARKING LAMPS ON position, the headlamp
switch routes voltage on 2 separate circuits back to the CJB. One circuit is for the front and rear
parking lamps and the other is for the license plate lamps. The voltage passes through CJB fuses
156 (7.5A) (LH parking lamps), 175 (7.5A) (RH parking lamps) and 157 (7.5A) (license plate lamps)
to the parking and license plate lamps.
The license plate lamps share a common ground circuit.
- Fuse
- Headlamp switch
- Headlamp assembly
PINPOINT TEST N: ONE OR MORE PARKING, REAR OR LICENSE PLATE LAMPS IS

INOPERATIVE
------------------------------------------------- N1 DETERMINE IF ALL THE PARKING LAMPS ARE

INOPERATIVE
- Ignition OFF.
- Place the headlamp switch in the PARKING LAMPS ON position.
- Are all the parking lamps inoperative?
Yes
PLACE the headlamp switch in the OFF position. VERIFY the CJB fuse 132 (10A) is OK. If OK, GO
to N2. If not OK, REFER to the Wiring Diagrams to identify the possible causes of the circuit short.
No
If both license plate lamps are inoperative, GO to N3.
If the front and rear parking lamps are inoperative, GO to N6.
If all the LH parking lamps are inoperative, VERIFY the CJB fuse 175 (7.5A) is OK. If OK, REPAIR
the circuit 29S-LF1 (OG/YE) for an open. TEST the system for normal operation. If not OK, REFER
to the Wiring Diagrams to identify the possible causes of the circuit short. See: Diagrams/Electrical
If all the RH parking lamps are inoperative, VERIFY the CJB fuse 156 (7.5A) is OK. If OK, REPAIR
the circuit 29S-LF1 (OG/YE) for an open. TEST the system for normal operation. If not OK, REFER
to the Wiring Diagrams to identify the possible causes of the circuit short. See: Diagrams/Electrical
For all other individual lamp concerns, GO to N7.
------------------------------------------------- N2 CHECK FOR VOLTAGE TO THE HEADLAMP SWITCH
- Measure the voltage between the headlamp switch C205-11, circuit 29-LE29 (OG/BK), harness
side and ground.
Yes

Switch/Service and Repair. TEST the system for normal operation.
No
REPAIR circuit 29-LE29 (OG/BK) for an open. TEST the system for normal operation.
------------------------------------------------- N3 CHECK FOR VOLTAGE TO THE LICENSE PLATE

LAMPS
- Disconnect: LH License Plate Lamp C452.
- Measure the voltage between the LH license plate lamp C452-2, circuit 29S-LF21 (OG/BK),
Yes
REPAIR the license plate lamps ground circuit. TEST the system for normal operation.
No
VERIFY the CJB fuse 157 (7.5A) is OK. If OK, GO to N4. If not OK, REFER to the Wiring Diagrams
to identify the possible causes of the circuit short. See: Diagrams/Electrical Diagrams/Diagrams By
Number
------------------------------------------------- N4 BYPASS THE HEADLAMP SWITCH (LICENSE PLATE

LAMPS)
- Connect: LH License Plate Lamp C452.
- Connect a fused jumper wire between the headlamp switch C202-11, circuit 29-LE29 (OG/BK),
harness side and the headlamp switch C202-16, circuit 29S-LF5 (OG/BU), harness side.
- Do the license plate lamps illuminate?
Yes
REMOVE the jumper wire. INSTALL a new headlamp switch. REFER to Headlamp Switch See:
Headlamp/Headlamp Switch/Service and Repair. TEST the system for normal operation.
No
LEAVE the jumper wire connected. GO to N5.
------------------------------------------------- N5 CHECK FOR VOLTAGE TO THE CJB FUSE 157 (7.5A)
NOTE: Make sure the CJB fuse 157 (7.5A) is installed and probe through one of the fuse openings.
- Measure the voltage between the CJB fuse 157 (7.5A) and ground.
Yes
REMOVE the jumper wire. REPAIR circuit 29S-LF21 (OG/BK) for an open. TEST the system for
normal operation.
No
REMOVE the jumper wire. REPAIR circuit 29S-LF5 (OG/BU) for an open. TEST the system for
normal operation.
------------------------------------------------- N6 BYPASS THE HEADLAMP SWITCH (FRONT AND

REAR PARKING LAMPS)
- Connect a fused jumper wire between the headlamp switch C202-11, circuit 29-LE29 (OG/BK),
harness side and the headlamp switch C202-13, circuit 29S-LF1 (OG/YE), harness side.
- Do the front and rear parking lamps illuminate?
Yes
REMOVE the jumper wire. INSTALL a new headlamp switch. REFER to Headlamp Switch See:
Headlamp/Headlamp Switch/Service and Repair. TEST the system for normal operation.
No
REMOVE the jumper wire. REPAIR circuit 29S-LF1 (OG/YE) for an open. TEST the system for
normal operation.
------------------------------------------------- N7 CHECK FOR VOLTAGE TO THE INOPERATIVE LAMP
- Place the headlamp switch in the OFF position.
- Disconnect: Inoperative Lamp.
- Place the headlamp switch in the PARKING LAMPS ON position.
- Measure the voltage between the inoperative lamp, harness side and ground as follows:
Yes
For a side marker lamp, REPAIR the ground circuit for an open. TEST the system for normal
operation.
For all other lamps, GO to N8.

No
REPAIR the voltage supply circuit for an open. TEST the system for normal operation.
------------------------------------------------- N8 CHECK FOR VOLTAGE TO THE INOPERATIVE LAMP

USING THE CONNECTOR GROUND
- Measure the voltage between the inoperative lamp, harness side as follows:
Yes
For a front lamp, REPAIR or INSTALL a new headlamp assembly. REFER to Headlamp Assembly
See: Headlamp/Service and Repair. TEST the system for normal operation.
For a rear lamp, REPAIR or INSTALL a new rear lamp jumper harness. TEST the system for
normal operation.
For a license plate lamp, INSTALL a new license plate lamp. REFER to License Plate Lamp See:
License Plate Lamp/Service and Repair. TEST the system for normal operation.
No
REPAIR the ground circuit in question for an open. TEST the system for normal operation.
-------------------------------------------------
Pinpoint Test O: The Parking, Rear Or License Plate Lamps Are On Continuously
Pinpoint Tests
Pinpoint Test O: The Parking, Rear Or License Plate Lamps Are On Continuously
Refer to Wiring Diagram Set 92, Parking, Rear and License Lamps for schematic and connector
Normal Operation
When the headlamp switch is placed in the PARKING LAMPS ON position, the headlamp switch
routes voltage on 2 separate circuits back to the Central Junction Box (CJB). One circuit is for the
front and rear parking lamps and the other is for the license plate lamps. The voltage passes
through CJB fuses 156 (7.5A) (LH parking lamps), 175 (7.5A) (RH parking lamps) and 157 (7.5A)
(license plate lamps) to the parking and license plate lamps.
The Generic Electronic Module (GEM) also has an output circuit spliced into the parking lamps
voltage supply circuit.
- Headlamp switch
- GEM
PINPOINT TEST O: THE PARKING, REAR OR LICENSE PLATE LAMPS ARE ON

CONTINUOUSLY
------------------------------------------------- O1 CHECK THE GEM
- Ignition OFF.
- Disconnect: GEM C201e.
- Ignition ON.
Do the parking lamps continue to illuminate?
Yes
If equipped with Daytime Running Lamps (DRL), GO to O2.
If not equipped with DRL, GO to O3.
No
GO to O7.
------------------------------------------------- O2 CHECK THE HEADLAMP SWITCH (VEHICLES WITH

DRL)
- Ignition OFF.
- Ignition ON.
- Do the parking lamps or the headlamps continue to illuminate?

Yes
If the license plate lamps continue to illuminate, GO to O4.
If the LH or RH parking lamps continue to illuminate, GO to O5.
If the headlamps continue to illuminate, GO to Pinpoint Test W. See: Daytime Running

Lamp/Testing and Inspection/Pinpoint Tests/Pinpoint Test W: The Daytime Running Lamps (DRL)
Are On With The Ignition Switch Off
No

------------------------------------------------- O3 CHECK THE HEADLAMP SWITCH (VEHICLES
WITHOUT DRL)
- Ignition OFF.
- Ignition ON.
- Do the parking lamps continue to illuminate?
Yes
If the license plate lamps continue to illuminate, GO to O4.
If the LH or RH parking lamps continue to illuminate, GO to O5.
No

------------------------------------------------- O4 CHECK THE LICENSE PLATE LAMP SUPPLY CIRCUIT

- Disconnect: CJB Fuse 157 (7.5A).
- Do the license plate lamps continue to illuminate?
Yes
REPAIR the license plate lamps supply circuit for a short to voltage. TEST the system for normal
operation.
No
REPAIR circuit 29S-LF5 (OG/BU) for a short to voltage. TEST the system for normal operation.
------------------------------------------------- O5 CHECK THE LH PARKING LAMPS SUPPLY CIRCUIT

- Do the LH parking lamps continue to illuminate?
Yes
REPAIR the LH parking lamps supply circuit for a short to voltage. TEST the system for normal
operation.
No
GO to O6.
------------------------------------------------- O6 CHECK THE RH PARKING LAMPS SUPPLY CIRCUIT

- Do the RH parking lamps continue to illuminate?
Yes
REPAIR the RH parking lamps supply circuit for a short to voltage. TEST the system for normal
operation.
No
REPAIR circuit 29S-LF1 (OG/YE) for a short to voltage. TEST the system for normal operation.
------------------------------------------------- O7 CHECK FOR CORRECT GEM OPERATION
- Check for: -
corrosion
- damaged pins
- pushed-out pins
Yes
INSTALL a new GEM. REFER to Body Control Systems. TEST the system for normal operation.
No
corroded connector.
-------------------------------------------------
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay >
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay >

Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay
> Component Information > Testing and Inspection > Relays - Micro
> Component Information > Testing and Inspection > Relays - Micro > Page 6023
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component
Information > Locations > Low Beam Relay
Information > Locations > Low Beam Relay > Page 6030
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Low Beam Relay >

Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
follows: -
Typical BPP Switch

strategy.
Stoplamp Switch

Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Door Ajar Switch, Left Front
Information > Diagrams > Door Ajar Switch, Left Front




Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
instrument panel.

Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Headlamp Switch

Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
Introduction
Note
been simplified.
Current Flow (1)
Diagrams.
Splices (3)
Component Names (5)
the wire color.
"Symbols".

Power Distribution
Ground Distribution
Charts.
WARNINGS
the procedure.
clothing.
Symbol
Symbols (Part 1)
Symbols (Part 2)
Symbols (Part 3)
Symbols (Part 4)
Symbols (Part 5)
Tail Lamp: Diagnostic Aids
terminal.
1 = Locked terminal
2 = Male half
3 = Female half
4 = Seal
7 = Seal
1 = Proper crimp
1 = Seal
2 = Displaced tab
3 = Female half
4 = Seal
6 = Male half
1 = Enlarged
2 = Normal
signal.

4 = Grounding foil
Splice covered 2
= Wire strand
3 = Splice tape
4 = Harness tape
2 = Wiring strand

NOTE: -

splice.
wire size
harness.
Tail Lamp: Connector Views
Lamp Assembly, Left Rear
Lamp Assembly, Right Rear

Tail Lamp: Electrical Diagrams
92-1
92-2
92-3
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 6133
Tail Lamp: Service and Repair
Rear Lamp Assembly
NOTE: The rear door is shown removed for clarity.

1. Remove the 2 fasteners and the rear lamp assembly.
2. If necessary, remove the bulb from the bulb holder.

Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Front
Turn Signal Lamp: Diagrams Turn Lamp, Left Front

Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Turn Lamp, Left Front > Page 6139
Turn Signal Lamp: Diagrams Turn Lamp, Right Front

Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations >
Page 6143
Page 6144
Page 6145
Page 6146
Page 6147
All vehicles
Steering Column.

Page 6148
All vehicles

Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component

Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component

Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay

Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >

Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element

Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Moulding / Trim.

Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Motor: Service and Repair Glass, Frames and Mechanisms - Exploded View,
Front Door

Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door > Page 6202
Front Door Window Motor: Service and Repair Window Regulator and Motor - Front Door

Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Page 6206

Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Testing and
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
> Page 6215
> Page 6216
> Page 6217
> Page 6218
> Page 6219
> Page 6220
> Page 6221
Moulding / Trim.

Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component
Back Window Glass: Service and Repair
Window Glass - Rear
Removal
All vehicles
1. If equipped, remove the rear window wiper motor assembly. For additional information, refer to
Wiper and Washer Systems.
2. If equipped, remove the rear window wiper motor shaft grommet.
Vehicles equipped with rear window defrost
3. If equipped, remove the screws and the rear window glass shield.
4. Detach the grommet from the rear door panel.
5. Disconnect the rear window defrost electrical connectors.
All vehicles
pinchweld area.
cutting.
replacement rear door glass.
Insert the Deluxe Windshield Removal Tool at the upper center of the rear door glass and work
10. Carefully remove the rear door glass from the vehicle and place on a stable work surface.
11. Remove and discard the rear door window glass weatherstrip.
Installation
All vehicles
1. Dry-fit the rear door glass on the existing urethane adhesive bead on the pinch weld.
- Position the rear door glass on the pinch weld.
- Make alignment marks with tape or non-staining grease pencil on the rear door glass and the
body.
upward.
5. If reinstalling the same rear door glass, remove the remaining urethane adhesive from the glass
leaving a thin layer to bond with the new urethane
adhesive bead.
6. Clean the inside of the rear door glass surface with glass cleaner.
If installing a new rear door glass, apply glass primer according to manufacturer's instructions.
8. Install a new rear door window glass weatherstrip.
NOTE: The rear door glass must be positioned within 10 minutes of applying the urethane
adhesive.
ending at the bottom of the rear door glass opening near the center, making sure there are no gaps
in the bead.
NOTICE: Before positioning the rear door glass, open vehicle windows to prevent the air pressure
of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the rear door glass on the pinch weld.
11. Using suitable tape, secure the rear door window glass in the correct position until the urethane
adhesive has cured.
water leaks.
After the urethane adhesive has cured, check the rear door glass seal for air or water leaks through
the urethane adhesive bead and add urethane adhesive as necessary.
Vehicles equipped with rear window defrost
13. Connect the rear window defrost electrical connectors.
14. Attach the grommet to the rear door panel.
15. If equipped, install the screws and the rear window glass shield.
All vehicles
16. If equipped, install the rear window wiper motor shaft grommet.
17. If equipped, install the rear window wiper motor assembly. For additional information, refer to
Wiper and Washer Systems.
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door
Window Glass Weatherstrip > Component Information > Service and Repair > Glass, Frames and Mechanisms - Exploded
View, Front Door

View, Front Door > Page 6235
straight up.

View, Front Door > Page 6236

Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Sliding Door Window Glass > System
Sliding Door Window Glass: Service and Repair
Window Glass - Sliding Door
Removal
pinchweld area.

cutting.
replacement sliding door glass.
NOTE: Some resistance may be encountered when cutting through the glass locating pegs in the
corners of the glass.
Insert the Deluxe Windshield Removal Tool at the upper center of the sliding door glass and work
5. Carefully remove the sliding door glass from the vehicle and place on a stable work surface.
6. Remove and discard the sliding door window glass weatherstrip.
Installation
1. Dry-fit the sliding door glass on the existing urethane adhesive bead on the pinch weld.
- Position the sliding door glass on the pinch weld.
- Make alignment marks with tape or non-staining grease pencil on the sliding door glass and the
body.
upward.
NOTE: Carefully remove the remaining part of the locating pegs from the sliding door window glass
opening.
5. If reinstalling the same sliding door glass, remove the remaining urethane adhesive from the
glass leaving a thin layer to bond with the new
urethane adhesive bead.
6. Clean the inside of the sliding door glass surface with glass cleaner.
If installing a new sliding door glass, apply glass primer according to manufacturer's instructions.
8. Install a new sliding door window glass weatherstrip.
NOTE: The sliding door glass must be positioned within 10 minutes of applying the urethane
adhesive.
ending at the bottom of the sliding door glass opening near the center, making sure there are no
gaps in the bead.
NOTICE: Before positioning the sliding door glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the sliding door glass on the pinch weld.
11. Using suitable tape, secure the sliding door window glass in the correct position until the
urethane adhesive has cured.
water leaks.
After the urethane adhesive has cured, check the sliding door glass seal for air or water leaks
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair > Glass, Frames and Mechanisms - Exploded View, Front Door
Front Door Window Regulator: Service and Repair Glass, Frames and Mechanisms - Exploded
View, Front Door

Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Front Door Window Regulator: Service and Repair Window Regulator and Motor - Front Door

Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield
Glass
Windshield: Service and Repair Windshield Glass
Windshield Glass
Glass > Page 6252
Removal
1. Remove the cowl panel grilles.
3. Remove the interior mirror. For additional information, refer to Mirrors.
pinchweld area.
cutting.
replacement windshield glass.
Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work
7. Using The Pumper, distance the windshield glass from the body.
9. Carefully remove the windshield glass from the vehicle and place on a stable work surface.
Installation
1. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
- Position the windshield glass on the pinch weld.
- Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
Glass > Page 6253
- Make alignment marks with tape or non-staining grease pencil (preferably at the windshield glass
stop blocks) on the windshield glass and the body.
upward.
5. If reinstalling the same windshield glass, remove the remaining urethane adhesive from the
glass leaving a thin layer to bond with the new urethane
adhesive bead.
6. Clean the inside of the windshield glass surface with glass cleaner.
7. Install the glass moulding.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions.
NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane
adhesive.
ending at the bottom of the windshield opening near the center, making sure there are no gaps in
the bead.
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air pressure
of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the windshield glass on the pinch weld.
water leaks.
After the urethane adhesive has cured, check the windshield glass seal for air or water leaks
12. Install the interior mirror. For additional information, refer to Mirrors.
Glass > Page 6254
13. Install the headliner.
14. Install the cowl panel grilles.

Glass > Page 6255
Windshield: Service and Repair Glass Reseal - Windshield
Glass Reseal - Windshield
1. Remove the cowl panel grilles.
3. Clean the interior and exterior of the windshield glass surface with glass cleaner.
4. Cut the urethane adhesive applicator tip to the specification.
5. NOTE: Use either the Air Caulking Gun or a high ratio, electric or battery-operated caulk gun that
will apply the urethane adhesive with less
effort and a continuous bead.
NOTE: Make sure there are no gaps in the urethane adhesive bead.
Apply urethane adhesive over the top of the existing urethane adhesive.
- Apply the urethane adhesive to the top and sides of the windshield from the interior of the vehicle.
- Apply the urethane adhesive to the bottom of the windshield from the exterior of the vehicle.
water leaks.
After the urethane adhesive has cured, check the windshield seal for air or water leaks through the
urethane adhesive bead and add urethane adhesive as necessary.
7. Install the headliner.
8. Install the cowl panel grille.

Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay

Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Locations
All vehicles
Steering Column.

All vehicles

Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations > Wiper/Washer Switch
Switch > Component Information > Locations > Wiper/Washer Switch > Page 6280
Switch > Component Information > Diagrams > Multifunction Switch
Switch > Component Information > Diagrams > Multifunction Switch > Page 6283
Switch > Component Information > Testing and Inspection > Wiper/Washer Switch
Switch > Component Information > Testing and Inspection > Wiper/Washer Switch > Page 6288
Switch > Component Information > Testing and Inspection > Page 6291
All vehicles
Steering Column.

Switch > Component Information > Testing and Inspection > Page 6292
All vehicles

Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations
Windshield Washer Motor: Locations
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams
Windshield Washer Pump: Diagrams
> Page 6299
> Page 6300
Windshield Washer Pump: Service and Repair
Washer Pump and Reservoir
Washer pump or fluid reservoir
1. NOTE: To prevent spilling windshield washer fluid, drain the washer reservoir before washer
pump removal.
Remove the washer fluid reservoir filler neck from the washer fluid reservoir in the following
sequence.
1. Remove the washer fluid reservoir filler neck bolt.
2. To install, tighten to 5 Nm (44 lb-in).
3. Rotate the filler neck while pulling away from the reservoir.
2. Remove the LH fender splash shield.
3. Detach the washer reservoir from the fender in the following sequence.
1. Remove the front bolt and the rear nut.
2. To install, tighten the bolt to 5 Nm (44 lb-in).
3. To install, tighten the nut to 6 Nm (53 lb-in).
4. Pull the reservoir away from the stud.
5. Lower the rear of the reservoir.
4. Disconnect the washer pump hose and the electrical connector.
NOTICE: A retaining clip is located between the reservoir and the vehicle body. Failure to remove
the reservoir in the following sequence may cause damage to the clip.
5. Remove the reservoir from the vehicle in the following sequence.
1. Move the reservoir forward.
2. Lift the reservoir upward.
3. Pull the reservoir away from the vehicle.
4. Lower the reservoir from the vehicle.
Washer pump only
6. Remove the washer pump from the fluid reservoir.

> Page 6301
7. NOTICE: Do not operate the washer pump prior to filling the washer reservoir. Failure to follow
this instruction may result in
premature washer pump failure.
- Fill the washer reservoir with windshield washer fluid.

Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
and Repair
Windshield Washer Reservoir: Service and Repair
Washer Pump and Reservoir
1. NOTE: To prevent spilling windshield washer fluid, drain the washer reservoir before washer
pump removal.
Remove the washer fluid reservoir filler neck from the washer fluid reservoir in the following
sequence.
1. Remove the washer fluid reservoir filler neck bolt.
2. To install, tighten to 5 Nm (44 lb-in).
3. Rotate the filler neck while pulling away from the reservoir.
2. Remove the LH fender splash shield.
3. Detach the washer reservoir from the fender in the following sequence.
1. Remove the front bolt and the rear nut.
2. To install, tighten the bolt to 5 Nm (44 lb-in).
3. To install, tighten the nut to 6 Nm (53 lb-in).
4. Pull the reservoir away from the stud.
5. Lower the rear of the reservoir.
4. Disconnect the washer pump hose and the electrical connector.
NOTICE: A retaining clip is located between the reservoir and the vehicle body. Failure to remove
the reservoir in the following sequence may cause damage to the clip.
5. Remove the reservoir from the vehicle in the following sequence.
1. Move the reservoir forward.
2. Lift the reservoir upward.
3. Pull the reservoir away from the vehicle.
4. Lower the reservoir from the vehicle.
Washer pump only
6. Remove the washer pump from the fluid reservoir.

Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service
7. NOTICE: Do not operate the washer pump prior to filling the washer reservoir. Failure to follow
this instruction may result in
premature washer pump failure.
- Fill the washer reservoir with windshield washer fluid.

Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations
> Page 6309
> Page 6310
> Page 6311
> Page 6312
> Page 6313
All vehicles
Steering Column.

> Page 6314
All vehicles

Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Pivot Arm - Front
Wiper Arm: Service and Repair Wiper Pivot Arm - Front
Wiper Pivot Arm - Front
1. Remove the wiper pivot arm nut cover.
2. NOTE: After the wiper pivot arm nut is removed, a suitable 2 jaw puller may be necessary to
remove the wiper pivot arm.
Remove the nut and the wiper pivot arm.
3. NOTE: Make sure there is no mechanical binding in the linkage preventing the wiper arms from
returning to the fully parked position.
- Verify that the RH windshield wiper blade is between the 2 alignment marks and the LH
windshield wiper blade is slightly above the alignment mark on the windshield.
Wiper Pivot Arm - Front > Page 6319
Wiper Arm: Service and Repair Wiper Pivot Arm - Rear
Wiper Pivot Arm - Rear
1. Pull the lower portion wiper pivot arm nut cover upward to access the wiper pivot arm nut.
2. NOTE: For proper installation, identify the washer jet nozzle position before removing the washer
jet nozzle.
Remove the washer jet nozzle.
- Pull the washer jet nozzle away from the wiper motor.
3. NOTICE: Failure to remove the washer jet nozzle before installing the removal puller, will
damage the washer jet nozzle.
NOTE: After the wiper pivot arm nut is removed, a suitable 2 jaw puller may be necessary to
remove the wiper pivot arm.
Remove the nut and the wiper pivot arm.
- To install, position the wiper blade vertically and tighten to 15 Nm (133 lb-in).

Wiper Pivot Arm - Front > Page 6320
Wiper Arm: Service and Repair Wiper Mounting Arm and Pivot Shaft - Front
Wiper Mounting Arm and Pivot Shaft - Front
Removal
1. Remove the upper and lower cowl panel grilles.
2. NOTICE: Do not remove the wiper motor linkage arm from the wiper motor assembly. If the arm
is removed, the wiper arms may not
park in the correct location and damage may occur.
Remove the 3 wiper mounting arm and pivot shaft bolts.
3. Disconnect the windshield wiper motor electrical connector.
4. Remove the wiper mounting arm and pivot shaft.
Installation
1. Position the wiper mounting arm and pivot shaft.
2. Connect the windshield wiper motor electrical connector.
3. Position the pivot shaft bracket guide pin hole to the cowl guide pin.
4. Install the 3 wiper mounting arm and pivot shaft bolts.
5. Install the upper and lower cowl panel grilles.

Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Blade: > 09-20-8 > Oct > 09 > Wipers/Washers - L/H/R/H Wiper Blade Interference
Wiper Blade: Customer Interest Wipers/Washers - L/H/R/H Wiper Blade Interference
TSB 09-20-8
10/19/09
PASSENGER WIPER ARM INTERFERES WITH DRIVER ARM IN PARK POSITION
ISSUE Some 2010 Transit Connect vehicles built before 7/12/2009 may exhibit a touch condition,
driver wiper blade to passenger wiper arm contact, when lifting the driver arm up off the windshield,
when in the park position.

SERVICE PROCEDURE
1. Replace the passenger wiper arm with a new designed arm. (Figure 1 B)
2. While installing the wiper arm and blade assembly, verify the park position of passenger side
wiper blade with respect to indicators on windshield.
Refer to Wiper Pivot Arm - Front in Workshop Manual (WSM), Section 501-16.
3. Run wiper system at high speed with wet glass to verify there is no wiper blade interference with
the A-pillar or cowl.
Parts Block
Replace The Passenger Side Wiper Arm (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17526 42
Bulletins > Customer Interest for Wiper Blade: > 09-20-8 > Oct > 09 > Wipers/Washers - L/H/R/H Wiper Blade Interference
> Page 6329
Disclaimer
Bulletins > All Technical Service Bulletins for Wiper Blade: > 09-20-8 > Oct > 09 > Wipers/Washers - L/H/R/H Wiper Blade
Interference
Wiper Blade: All Technical Service Bulletins Wipers/Washers - L/H/R/H Wiper Blade Interference
TSB 09-20-8
10/19/09
PASSENGER WIPER ARM INTERFERES WITH DRIVER ARM IN PARK POSITION
ISSUE Some 2010 Transit Connect vehicles built before 7/12/2009 may exhibit a touch condition,
driver wiper blade to passenger wiper arm contact, when lifting the driver arm up off the windshield,
when in the park position.

SERVICE PROCEDURE
1. Replace the passenger wiper arm with a new designed arm. (Figure 1 B)
2. While installing the wiper arm and blade assembly, verify the park position of passenger side
wiper blade with respect to indicators on windshield.
Refer to Wiper Pivot Arm - Front in Workshop Manual (WSM), Section 501-16.
3. Run wiper system at high speed with wet glass to verify there is no wiper blade interference with
the A-pillar or cowl.
Parts Block
Replace The Passenger Side Wiper Arm (Do Not Use With Any Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
17526 42
Bulletins > All Technical Service Bulletins for Wiper Blade: > 09-20-8 > Oct > 09 > Wipers/Washers - L/H/R/H Wiper Blade
Interference > Page 6335
Disclaimer
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Wiper
Motor Assembly, Left
Wiper Motor: Locations Rear Wiper Motor Assembly, Left
Motor Assembly, Left > Page 6340
Wiper Motor: Locations Rear Wiper Motor Assembly, Right
Wiper Motor: Locations Windshield Wiper Motor
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper
Motor Assembly, Left
Wiper Motor: Diagrams Rear Wiper Motor Assembly, Left

Wiper Motor: Diagrams Rear Wiper Motor Assembly, Right

Wiper Motor: Diagrams Windshield Wiper Motor
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield
Wiper Motor: Service and Repair Wiper Motor - Windshield
Wiper Motor - Windshield
1. Remove wiper mounting arm and pivot shaft. For additional information, refer to Wiper Mounting
Arm and Pivot Shaft - Front See: Wiper
Arm/Service and Repair/Wiper Mounting Arm and Pivot Shaft - Front.
2. Remove the wiper motor arm nut.
3. Disconnect the arm from the wiper motor.
4. Remove the 3 bolts and the wiper motor.

Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Wiper Motor - Windshield > Page 6349
Wiper Motor: Service and Repair Wiper Motor - Rear Window
Wiper Motor - Rear Window
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear
See: Wiper Arm/Service and Repair/Wiper Pivot
Arm - Rear.
2. Remove the 3 nuts and the wiper motor cover.
3. Disconnect the washer fluid hose and electrical connector from the wiper motor.
4. Remove the 3 nuts and the wiper motor.
- Verify the window grommet is properly seated before installing the wiper motor.
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations

Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Testing and Inspection >
Relays - Micro
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations >
Wiper/Washer Switch
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations >
Wiper/Washer Switch > Page 6362
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams >
Multifunction Switch
Multifunction Switch > Page 6365
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection
> Wiper/Washer Switch
> Wiper/Washer Switch > Page 6370
> Page 6373
All vehicles
Steering Column.

Ford Transit Connect Workshop Manual l4 2 0l 2010

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Communications Control Module: Diagrams Audio Control Module (ACM)

Communications Control Module: Diagrams In-Dash Computer

Communications Control Module: Diagrams In-Dash Computer Junction Box

Communications Control Module: Diagrams Telematics Module

Communications Control Module: Procedures

Ford Work Solutions(TM) Self-Diagnostic Mode

In-Dash Computer Self-Diagnostic Mode

1. Turn the in-dash computer on and navigate to the home screen.

3. The following diagnostic routines are available:

- The system automatically restarts in normal mode.

In-Dash Computer Software Level Check

1. Turn the in-dash computer on.

3. The following information (relevant to service) is displayed:

Internet Connection Manager

1. Turn the in-dash computer on.

3. The following information (relevant to service) is displayed:

Tool Link(TM) Diagnostic Test

1. Turn the in-dash computer on.

3. Scroll down and select the TOOL LINK icon.

4. Select SERVICES, then STATUS.

5. The following information (relevant to service) is displayed:

Navigation Diagnostic Screen

1. Turn the in-dash computer on.

Communications Control Module: Removal and Replacement

Audio Control Module (ACM)

Audio Control Module (ACM)

Management/Computers and Control Systems/Information Bus/Testing and

Center Instrument Panel Finish Panel

Removal and Installation

2. Remove the 4 screws and the in-dash computer.

- Disconnect the electrical connectors.

3. To install, reverse the removal procedure.

1. Turn the ignition to OFF.

2. Remove the instrument panel fuse box cover.

3. Disconnect the telematics module electrical connector.

4. Remove the telematics module.

1. Remove the 2 screws.

3. Remove the telematics module.

2. Connect the telematics module electrical connector.

3. Install the instrument panel fuse box cover.

4. Initialize the telematics module.

1. Wait 5 minutes after the modem-antenna is installed.

2. Turn the ignition to RUN.

4. Start the vehicle and run the engine for 30 seconds.

5. Turn the ignition to OFF.

Tool Link(TM) Reader

Tool Link(TM) Reader

Removal and Installation

- Disconnect the electrical connectors.

6. To install, reverse the removal procedure.

Parking Assist Control Module: Diagrams

Parking Assist Control Module: Service and Repair

Parking Aid Module (PAM)

Removal and Installation

1. Remove the Central Junction Box (CJB) fuse panel cover.

2. If replacing the Parking Aid Module (PAM) only, proceed as follows:

- Disconnect the electrical connectors.

- Remove the 2 bolts and the PAM.

3. If replacing the parking aid speaker only, proceed as follows:

- Disengage the parking aid speaker clips.