Ford Freestar Mercury Monterey Wiring Diagrams

Page 979 Inspection Page 8722 Page 450 P0355 - P0359: Testing and Inspection P0356 For diagnosis of code P0356 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5701 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 Service and Repair Rocker Arm Assembly: Service and Repair Rocker Arms, Valve Springs, Push Rods, Valve Tappets Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location. 1. Remove the valve cover. 2. If removing the valve tappets, remove the lower intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Windshield Wiper Motor View 151-4 Page 5662 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Removal and Installation 1. Raise and support the vehicle. NOTE: Clean the area around the sensor hole prior to removal. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 3: Wheel Speed Sensor Installation Note 1. Lube the O-ring before installing a new wheel speed sensor. Locations Page 7031 9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any foreign material from the grooves with a lint-free cloth. CONNECT 1. Install the spring lock coupling spring. 2. Lubricate the inside of the coupling with mineral oil. 3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seals. Lubricate the O-ring seals with mineral oil. System Diagnosis P0790 - P0794: Testing and Inspection For diagnosis of code P0793 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 7484 Page 3055 Page 5935 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do P0740 P0740 - P0744: Testing and Inspection P0740 Torqshift For diagnosis of code P0740 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 6505 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. System Diagnosis P1545 - P1549: Testing and Inspection For diagnosis of code P1549 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 977 Inspection Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The fuel tank pressure (FTP) sensor (Figure 103) or inline fuel tank pressure (FTP) sensor (Figure 104) is used to measure the fuel tank pressure during the EVAP Leak Check Monitor. Page 7349 1. Pull out to release the retaining clips. - If equipped, disconnect the electrical connectors necessary for removal. Item 3: Large Electrical Connector Removal Note 1. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Item 3: Large Electrical Connector Installation Note Page 5563 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 5929 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 7512 Engine Cooling Fan Relay 1 Page 3034 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Locations View 151-6 System Diagnosis P0160 - P0164: Testing and Inspection For diagnosis of code P0161 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1466 P2130 - P2134: Testing and Inspection P2133 For diagnosis of code P2133 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 10 P0010 - P0014: Testing and Inspection P0011 For diagnosis of code P0011 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 532 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3234 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Items 1-3: Rocker Arm Removal Note 1. If the rocker arms are to be reused, they must be installed in their original location. Mark the rocker arms for location before removing. 2. If removing valve springs, rotate the crankshaft until the piston is at the top of its stroke with both the intake and exhaust valves closed prior to removing the rocker arm. Item 7: Valve Tappet Removal Note Page 8764 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Locations View 151-13 Page 4407 Page 5219 11. Remove the plug from the cooler tube fitting. 12. Remove the flex hose from the cooler tube. 13. NOTE: Clean the cooler tube fitting before installing it to verify a good connection and to prevent any leaks. Install the lower cooler tube. 14. Install the lower retaining clip 15. Fill the transaxle with clean automatic transmission fluid. 16. Start the engine and move the transaxle range selector lever through all the ranges allowing the transaxle to engage in each position. 17. Check the transaxle at normal operating temperature. Fluid should be within the crosshatched area of the fluid level indicator. If the fluid is not within the crosshatched area add fluid in 0.2365 liter (1/2 pint) increments until the correct level is achieved. Locations View 151-1 Page 578 P0530 - P0534: Testing and Inspection P0534 For diagnosis of code P0534 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service and Repair Housing Assembly HVAC: Service and Repair PLENUM CHAMBER, ASSEMBLY AND COMPONENTS REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Instrument Panel Removal Note 1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair INSTALLATION 1. To install, reverse the removal procedure. Page 1250 P1635 - P1639: Testing and Inspection P1636 For diagnosis of code P1636 refer to NOTE 22: NOTE 22: DTC P1636 indicates the PCM has lost communication with the inductive signature chip. Replace the PCM. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9560 Special Tool(s) Quarter Panel Speaker Speaker: Service and Repair Quarter Panel Speaker QUARTER PANEL SPEAKER REMOVAL NOTE: The removal and installation procedures apply to all original equipment rear quarter panel speakers. 1. Remove the trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8715 View 151-21 Page 2438 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4913 Fuel Pressure Sensor/Switch: Description and Operation Natural Gas Fuel System INJECTION PRESSURE SENSOR Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 4873 Page 5146 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Steering Column Opening Cover Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Page 1474 P0603-P2198 / U0309-U2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 74 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8003 Climate Controlled Seat Module, Driver Side View 151-16 Page 2771 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 171 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3367 Part 2 Of 2 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. 5. NOTE: Tighten the oil filter one-half turn after the gasket makes contact with oil filter housing. Fill the engine with clean engine oil. Drain the engine oil. - Install a new engine oil filter. - Fill the engine with clean engine oil. Items 5-6: Lower Intake Manifold Bolt Removal Note 1. Note the location of the six long bolts and the eight short bolts. Items 11-7: Lower Intake Manifold and Gaskets Installation Note 1. Clean all gasket sealing surfaces with metal surface cleaner. Condenser to Evaporator Line Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Remove the wiper motor and pivot assembly. Page 6444 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 7184 Page 2308 Headlamp Switch: Testing and Inspection Page 403 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8666 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Locations View 151-13 Exhaust Manifold-LH Exhaust Manifold: Service and Repair Exhaust Manifold-LH Exhaust Manifold-LH 1. With the vehicle in neutral, position it on a hoist. 2. Remove the dual converter Y-pipe. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Item 2: EGR Tube-to-Exhaust Manifold Nut Removal Note Page 3996 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 3446 - Tighten the engine front cover studs to 7 Nm (62 inch lbs.). - Using a new gasket, install the coolant pump. - Tighten the fasteners in the sequence shown. Tighten bolt No. 12 to 10 Nm (89 inch lbs.). - Tighten all other fasteners to 28 Nm (21 ft. lbs.). 5. Install the two oil pan bolts and tighten to 10 Nm (89 inch lbs.). 6. Install the catalyst monitor sensor electrical connector bracket. 7. Connect the catalyst monitor sensor electrical connector. Item 9: Crankshaft Front Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation. Assemble the special tools, then place the crankshaft front seal onto the special tools. Page 4539 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8884 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied/Brake Deactivator Switch BRAKE PRESSURE APPLIED/BRAKE DEACTIVATOR SWITCH The brake pressure applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, which supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: Customer Interest Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 9489 Headlamp Switch: Service and Repair HEADLAMP SWITCH REMOVAL CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch assembly. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2419 View 151-6 Page 4040 Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 P1232 P1230 - P1234: Testing and Inspection P1232 For diagnosis of code P1232 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6298 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 7553 The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 2: Utility Compartment Removal Note Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Bussed Electrical Center (BEC) Fuse: Application and ID Bussed Electrical Center (BEC) Page 6710 Disclaimer Front Camber and Caster Adjustment Alignment: Service and Repair Front Camber and Caster Adjustment Front Camber and Caster Adjustment 1. Remove the cowl top vent panel. 2. Center punch the four spot welds. 3. Loosen the nuts. 4. CAUTION: Do not cut deeper than necessary to remove the alignment plate. Using the special tool, remove the four spot welds. 5. Remove the nuts and the alignment plate. Page 7146 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) US F7AZ-19589-DA (Motorcraft YN-12-C) .............................................................................................................................................. WSH-M1C231-B Canada F7AZ-19589-DA (Motorcraft CYN-12-C) ........................................................................................................................................... WSH-M1C231-B Page 9509 Symbols Part 4 Page 8058 Specifications Firing Order: Specifications 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 switch1 causing the magnetic field to collapse inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 6-tower, 6-tower horizontal and series 5 6-tower models (Freestar/Monterey/F 150 Heritage 3.9/4.2L). 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. 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. Page 7249 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 9368 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Service Precautions Memory Positioning Module: Service Precautions CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Page 791 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0782 refer to chart If there is no link in the chart then: Page 1022 P1260 - P1264: Testing and Inspection P1264 OBD II - Base Gasoline For diagnosis of code P1264 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8271 Page 2575 Impact Sensor: Description and Operation IMPACT SENSORS WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The RCM incorporates integral sensors that are not separately serviceable. All vehicles will have a front impact severity sensor located behind the front radiator grille under the hood latch assembly. There are two side impact sensors located under the front seats beneath the carpet. In addition there are two side impact sensors mounted near the driver and passenger C-pillars when the vehicle is equipped with driver and passenger safety canopy modules/seat side air bags. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all impact sensors. Page 8389 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 610 B1219-B1317 / P0182-P1272 Note 5: Clear the DTC and retest. If the DTC is retrieved again, check for aftermarket performance products before replacing the AFCM. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3728 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: All Technical Service Bulletins Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer System Diagnosis P0840 - P0844: Testing and Inspection For diagnosis of code P0841 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle A/C - Compressor Leaking/Inoperative Compressor Shaft Seal: All Technical Service Bulletins A/C - Compressor Leaking/Inoperative TSB 06-4-9 03/06/06 A/C COMPRESSOR NOT OPERATIONAL / LOW FREON-SHAFT SEAL LEAKS FORD: 2003 Escort 2003-2006 Focus, Mustang, Taurus 2003 Explorer Sport, Windstar 2003-2005 Excursion, Explorer Sport Trac 2003-2006 Escape, F-150, F-Super Duty, Ranger 2004-2006 Freestar 2006 Low Cab Forward LINCOLN: 2002 Blackwood 2006 Mark LT MERCURY: 2003-2005 Sable 2004-2006 Monterey 2005-2006 Mariner ISSUE Some 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal. ACTION Replace the A/C compressor shaft seal following the Service Procedure. SERVICE PROCEDURE If the shaft seal on the front of the A/C compressor is leaking, replace the shaft seal (F1VY-19D665-A) and not the compressor assembly. Replacing the shaft seal should correct the leaking condition. When replacing the seal, follow the procedure outlined in Workshop Manual, Section 412-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060409 Use Standard Labor Actual Operation For Compressor Time Removal And Installation If Available, And Claim Additional Labor Required As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19D665 42 Page 6395 Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 5547 Page 4698 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 7256 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 2570 Page 1528 Page 3756 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 367 P0275 - P0279: Testing and Inspection P0277 For diagnosis of code P0277 refer to chart B1219-B1317 / P0182-P1272 Page 1908 View 151-14 Page 2443 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. P2105 P2105 - P2109: Testing and Inspection P2105 For diagnosis of code P2105 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 3576 1. Disconnect the fluid cooler tubes from the connector assembly. ^ Push the fluid cooler tube inward slightly, squeeze the retaining clip, and with a slight twisting motion, pull the fluid cooler tube out of the connector assembly. Item 15: Radiator Support Bolts Removal Note 1. Detach the power steering lines from both sides of the radiator lower support. 2. Remove the bolt and position the A C muffler bracket aside. Item 19: Radiator Removal Note 1. Lower the vehicle, cut the mechanic's wire and remove the radiator, cooling fans and shroud as an assembly. Page 6640 Page 23 P0020 - P0024: Testing and Inspection P0022 For diagnosis of code P0022 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3613 Heater Hose: Vehicle Damage Warnings CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. Page 176 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2989 Refrigerant: Service and Repair Identifying Refrigerants IDENTIFYING REFRIGERANTS Refrigerant Identifier With Air-Radicator SPECIAL TOOL(S) Refrigerant Identification 1. NOTE: An A/C refrigerant analyzer 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 identifier to obtain the sample for testing. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode (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 diagnostic tool 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 diagnostic tool has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool 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. Page 4021 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 7633 Part 2 Page 7555 1. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. 3. NOTE: The RCM has been removed for clarity. Door Ajar Switch, Left Front View 151-18 Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Without Auxiliary Climate Control ........................................................................................................ ....................................................... 36 oz (1.50 kg) With Auxiliary Climate Control ............................................................................................................. ....................................................... 53 oz (1.59 kg) Page 409 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Trailer Tow Relay, Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 4740 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Page 5667 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 468 P0400 - P0404: Testing and Inspection P0401 For diagnosis of code P0401 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8725 Page 265 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0202 refer to chart Page 3646 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 5 Page 1132 P1405 - P1409: Testing and Inspection P1409 For diagnosis of code P1409 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1331 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8540 Paint: Application and ID Paint Code Sticker Location VEHICLE CERTIFICATION LABEL REFERENCE The VC label is located on the left-hand front door or door jamb and is in a similar location on trucks. Forward Crash Sensor Page 9218 Special Tool(s) Page 6746 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Page 4184 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 6132 Page 6204 Note: The bussed electrical center is located in the engine compartment. Page 748 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0753 refer to chart If there is no link in the chart then: Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Gasoline Fuel System Fuel Pressure Sensor/Switch: Description and Operation Gasoline Fuel System FUEL RAIL PRESSURE SENSOR Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 36) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 37) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve 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. Page 7709 Page 1035 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1267 refer to chart Page 7138 Refrigerant: Service and Repair Handling of Contaminated Refrigerants HANDLING OF CONTAMINATED REFRIGERANTS CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air conditioning 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 your area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Page 7714 Seat Belt Tensioner: Description and Operation Safety Belt System SAFETY BELT PRETENSIONERS The front safety belt buckles use a safety belt pretensioner system. This works in conjunction with the front air bag system mounted in the steering wheel and instrument panel. The pretensioner is a pyrotechnic device that removes excess webbing slack from the safety belt. When the pretensioner deploys in the buckle, excess slack is removed from the lap and shoulder safety belt. The pretensioners are activated when the restraints control module (RCM) detects a frontal impact force exceeding a programmed limit. If the vehicle is involved in a collision that results in deployment of the safety belt pretensioners, a new driver and passenger seat belt system (including safety belt buckle and pretensioners or safety belt retractor and pretensioners, safety belt retractors, safety belts, buckles and height adjusters), must be installed. Page 8068 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 3076 Page 3438 Part 3 Of 3 To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. Page 9463 View 151-22 Page 1329 Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7622 Seat Belt: Vehicle Damage Warnings CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F), for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. Page 2364 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 3634 Page 5697 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 Page 5199 ^ Taurus with floor shifter (Figure 7) 12. Connect the shift cable, if removed. 13. Install the air cleaner cover and outlet pipe. NOTE USE THE ALIGNMENT NOTCHES TO CORRECTLY ALIGN THE AIR CLEANER COVER TO THE AIR CLEANER TRAY. 14. Install the air cleaner housing clamp(s). 15. Connect the air cleaner outlet pipe to the throttle body and tighten to 35 lb-in (4 N.m). 16. Connect the crankcase vent tube to the air cleaner outlet pipe. 17. Connect the MAF sensor electrical connector. 18. Windstar, Freestar, and Monterey only, follow TSB 06-14-10 to seal and install the cowl panel grille. Parts Block OTHER APPLICABLE ARTICLES: 06-14-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061813A 2000-2007 Taurus, 0.5 Hr. 2000-2005 Sable: Replace Transaxle Vent Following Page 1276 P1700 - P1704: Testing and Inspection P1704 For diagnosis of code P1704 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Seat Adjust Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Adjust Switch, Driver Side Front Page 8635 Seat Cushion: Vehicle Damage Warnings CAUTION: - Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam pad. - If replacing only the front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the vehicle has not been exposed to temperatures below 6°C (42°F) or above 36°C (97°F) within four hours prior to the rezeroing process. If the vehicle has been exposed to temperatures outside the temperature limits (6-36°C), the vehicle must be exposed and kept at a temperature within the limits for a minimum of four hours. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum five second time period has passed after cycling the ignition switch ON before the rezeroing process. - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. Page 2627 Part 1 Page 5441 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 6329 Page 8109 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 857 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5923 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 7587 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Page 3697 which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Electronic Throttle Control System Strategy GEN II ETC System As stated earlier the torque based ETC strategy was developed mainly to improve fuel economy and to accommodate Variable Cam Timing. This is possible by not coupling the throttle angle to the drivers pedal position. By uncoupling the throttle angle (produce engine torque) from pedal position (driver demand). This allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. ETC is used on the 2004 MY Lincoln LS and Ford Thunderbird, Explorer/Mountaineer, and the new light-duty F-series. Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 2966 Engine Oil: Fluid Type Specifications Engine Oil .......................................................................................................................SAE 5W-20 Premium Synthetic Oil XO-5W20-QSP or equivalent Ford specification ............................................. ........................................................................................................................................... WSS-M2C153-H Page 104 P0115 - P0119: Testing and Inspection P0119 For diagnosis of code P0119 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 902 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6548 Disclaimer Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Page 7554 1. Pull out to release the retaining clips. - If equipped, disconnect the electrical connectors necessary for removal. Item 3: Large Electrical Connector Removal Note 1. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Item 3: Large Electrical Connector Installation Note Page 5401 Part 1 Of 3 Part 2 Of 3 Page 879 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 422 P0330 - P0334: Testing and Inspection P0331 For diagnosis of code P0331 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6875 Air Door Actuator / Motor: Diagrams Mode Door Actuator Page 9626 View 151-9 Diagrams Page 5169 ^ Windstar, Freestar, Monterey, Taurus, and Sable with column shifter - Must face to the right rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 1) ^ Taurus and Sable with floor shifter - Must face to the rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 2) 10. Install one end of a 24" (61 cm) long piece of 5/16" (8 mm) vacuum hose to the 90° vent stem and secure with a small hose clamp. 11. Route the vacuum hose back and up to the cowl area and down next to the brake master cylinder. Carefully tie rap the hose in place next to the brake master cylinder (do not tie rap to brake lines), be sure the end of the hose is facing down and not directly above anything hot. Page 4244 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Locations View 151-5 Page 1180 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6906 Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Locations View 151-10 Page 969 P1165 - P1169: Testing and Inspection P1169 For diagnosis of code P1169 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9466 Page 4627 Leak Detection Valve: Service and Repair EVAPORATIVE EMISSION CANISTER VENT SOLENOID REMOVAL WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery negative cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Carry out the evaporative emission system leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test 3. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Page 5669 View 151-29 Page 7045 Evaporator Case: Service and Repair Heater Core and Evaporator Core Housing, Assembly and Components HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - If removing the heater core only, refer to Heater Core - Front. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. - Lubricate the coolant hoses with plain water only if needed. 1. Recover the refrigerant. 2. Remove the wiper motor and pivot assembly. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Page 6226 Relay Box: Application and ID Bussed Electrical Center (BEC) Page 6480 Note: The bussed electrical center is located in the engine compartment. Page 577 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8078 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 6615 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Locations View 151-13 Page 795 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6980 7. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 8. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 9. Engage the special tool into the inside diameter of the shaft seal. 10. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. Page 2632 Part 2 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. Page 657 P0710 - P0714: Testing and Inspection P0712 Torqshift For diagnosis of code P0712 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2567 4F50N (AX4N) Electronic Shift Automatic Transmission Transmission Cooler: Service and Repair 4F50N (AX4N) Electronic Shift Automatic Transmission Transmission Fluid Cooler Backflushing and Cleaning Material 1. Carry out backflushing with a suitable torque converter/fluid cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated. 2. To aid in attaching the cleaner to the transmission steel cooler tube, connect two additional rubber hoses to the transaxle end of the steel transaxle cooler tube as follows: 1 Connect the cleaner tank pressure tube to the steel transaxle cooler return tube. 2 Connect a tank return hose to the steel transmission cooler pressure tube. Place the outlet end of this hose in the fluid tank reservoir. 3. Turn on pump and allow the fluid to circulate a minimum of five minutes (cycling switch on and off will help dislodge contaminants in cooler system). 4. Switch off the pump and disconnect the pressure hose from the transaxle cooler return tube. 5. Use compressed air to blow out the cooler(s) and tubes (blow air into the transaxle cooler return tube) until all is removed. 6. Remove the rubber return hose from the remaining steel cooler tube. Page 2488 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4419 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 7275 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. Page 3019 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 793 P0780 - P0784: Testing and Inspection P0783 4R70W For diagnosis of code P0783 refer to chart Part 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service and Repair Control Arm: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Hydraulic Control Assembly - Antilock Brakes: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 9185 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 7026 Coupler HVAC: Description and Operation THE SPRING LOCK COUPLING Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the couplings. - Use only the O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. PEANUT FITTING General Procedures Keyless Entry Key-Pad: Service and Repair General Procedures KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation will erase the stored customer code. The door locks lock, then unlock, confirming the code is erased. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. The door locks lock and unlock to confirm the new code is programmed. Page 3718 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 1806 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Main Climate Control Hose/Line HVAC: Description and Operation Main Climate Control REFRIGERANT LINES NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The compressor manifold and tube assembly is attached to the A/C compressor, is sealed with O-ring seals, and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure transducer. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure transducer can be removed without discharging the A/C system. Page 9612 Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus, use type B (Figure 3). NOTE DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL. SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE BUSS-BAR ON GOOD CONDUCTIVE MATERIAL. 1. Place the replacement terminal over the original tab location making sure the conductive areas of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original location which does not have conductive material (figure 4). 2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle may allow the terminal to slip when the solder liquefies). 3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab. Energize the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30) seconds. 4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for another two (2) minutes before the wiring lead is attached to the terminal. 5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify operation. Parts Block Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 2972 Power Steering Fluid: Specifications Power Steering Fluid Type ................................................................................................................................... Motorcraft MERCON ATF XT-2-QDX Locations View 151-11 Page 9662 Page 869 P0980 - P0984: Testing and Inspection P0984 For diagnosis of code P0984 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 1478 Inspection Page 832 P0960 - P0964: Testing and Inspection P0963 Torqshift For diagnosis of code P0963 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4879 Fuel Pump Relay: Testing and Inspection Page 3381 Page 8986 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Page 1155 P1460 - P1464: Testing and Inspection P1462 For diagnosis of code P1462 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4512 Page 3121 System Diagnosis P1725 - P1729: Testing and Inspection For diagnosis of code P1729 refer to chart P1641-P2106 NOTE 24: Refer to Transfer Case. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2199 Page 3028 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Page 5404 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Page 9476 Headlamp Dimmer Switch: Testing and Inspection Page 9518 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. Page 4000 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 6876 Page 6459 Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 7087 Heater Core Case: Service and Repair HEATER CORE AND EVAPORATOR CORE HOUSING, ASSEMBLY AND COMPONENTS REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - If removing the heater core only, refer to Heater Core - Front. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. - Lubricate the coolant hoses with plain water only if needed. 1. Recover the refrigerant. 2. Remove the wiper motor and pivot assembly. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair Page 2404 Intake Air Temperature Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 2873 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater hose away from the heater core tube. 5. Spread the retainer tabs apart and slide the retainer off the tube. - Discard the retainer. CONNECT 1. Clean the tubes and lubricate with coolant hose lubricant or plain water. 2. Install a new coupling retainer into the heater hose coupling housing. 3. Push the heater hose coupling onto the tube. 4. Make sure the heater hose coupling is fully engaged by lightly pulling on the heater hose. Page 1014 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1261 refer to chart Page 8728 Page 6375 Fuse Block: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 6649 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 2738 Windshield Washer Switch: Testing and Inspection Page 6134 Locations View 151-5 Specifications Valve Body: Specifications Valve body-to-pump ............................................................................................................................ .................................................. 10 Nm (89 inch lbs.) Valve body/solenoid-to-chain cover ...................................................................................................................................................... 10 Nm (89 inch lbs.) Page 1571 View 151-16 Page 726 - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0743 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection With Remote Audio Controls Cruise Control Switch: Service and Repair With Remote Audio Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2955 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... .................................................................. MERCON Page 6478 Relay Box: Locations Bussed Electrical Center (BEC) Left Page 2284 View 151-22 Page 7744 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Technician Safety Information Evaporative Check Valve: Technician Safety Information WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions may result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. Page 8135 Page 9771 Wiper Motor: Testing and Inspection COMPONENT TEST - WINDSHIELD WIPER MOTOR CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also damage the motor magnets. NOTE: - The windshield wiper motor component test is carried out to determine if the windshield wiper motor and module are functional and not in a software safe mode. Refer to Principles of Operation for software safe mode parameters. - Battery voltage must remain within 10 to 15 VDC to carry out test and keep windshield wiper motor from entering its software safe mode. - When connecting the power and ground test leads to the windshield wiper motor terminals, care must be taken to not short terminals between power and ground, as well as making sure the logic ground, pin 3, is always securely connected to prevent permanent windshield wiper motor module damage. If the windshield wiper motor does not pass any of the following tests, install a new windshield wiper motor. Use the SABRE Premium Battery and Electrical System Tester to test the windshield wiper motor. To test the windshield wiper motor, remove the windshield wiper mounting arm and pivot shaft from the windshield wiper motor. Disconnect the wiper motor. Connect the (1) green lead from the (2) SABRE to the battery negative (-) post. Connect the red lead (3) from the SABRE to the wiper motor (4) component side connector ground and logic ground pins 6 and 3 (3). Connect battery positive cable (5) to windshield wiper motor (4) component side connector battery and logic positive pins 5 and 8 (5). Low Speed Test the low speed mode by connecting a separate set of test leads from battery ground (-) post to windshield wiper motor (4) component side pins 9 and 10 (6). When these pins are grounded, the windshield wiper motor operation should now be in low speed mode. High Speed Test the high speed mode by connecting a separate set of test leads from battery ground (-) post to windshield wiper motor (4) component side pins 1, 9, and 10 (7). When these pins are grounded, the windshield wiper motor operation should now be in high speed mode. Washer Pump Relay (Integral) Test the windshield wiper motor internal washer relay function by measuring the voltage between windshield wiper motor (4) component side pin 7 (8), and ground while grounding the windshield wiper motor (4) component side pin 12 (9). When wash command input pin 12 is grounded, measured voltage should read 10 volts or greater. Page 9528 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 3126 Page 4738 Page 114 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 721 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Electrical - Wiring Harness Replacement Guidelines Wiring Harness: All Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Page 3478 Firing Order: Locations Page 6461 Page 6755 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Trailer Tow Relay, Parking Lamp Service and Repair Air Cleaner Housing: Service and Repair AIR CLEANER ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Air Cleaner Cover Removal Note 1. NOTE: No tools are needed to remove the air cleaner cover. Removal should be carried out using hands only. Release the clamps and separate the air cleaner cover from the air cleaner tray. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Overhead Console Removal Note 1. The overhead console is held in place by spring clips located on the panel. Item 3: Parking Aid Switch Removal Note 1. Release the tabs and remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Page 5960 Page 8293 1. Slide the control module off the drive assembly actuator. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Screw Installation Note 1. CAUTION: Do not operate the PSD drive assembly actuator with the cables disconnected or damage to the drive assembly actuator may occur. NOTE: Verify that the cable does not rub against the sheet metal. Make sure the cable pulley is fully through the opening. 2. NOTE: Make sure the safety belt is routed on top of the cable conduit. The cable eyelet clip cannot be reused. Always install a new clip. 3. Initialize both power sliding doors. Page 6283 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Page 7819 Arming and Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. 12. NOTE: When installing a new occupant classification sensor, a prepaid return postcard is provided with the new occupant classification sensor. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company. When returning the inoperative occupant classification sensor, include the following: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only). Item 1: Occupant Classification Sensor (OCS) (For OCS Service Kit) Installation Note 1. Bend the tab back on the pressure sensor component bracket. 2. CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. If equipped with heated seats, make sure the wire harness is accessible after trim cover attachment. Page 8220 3 Check for correct male to female wedge alignment. 4 Gently tap the male wedge into place if necessary. 5 Tighten the screws. Page 3111 Page 8998 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 990 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 246 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-6 Page 3811 View 151-5 Service and Repair Door Sensor/Switch (For Alarm): Service and Repair DOOR DISARM SWITCH - DRIVER DOOR REMOVAL 1. Remove the driver door trim panel. 2. Position the watershield aside. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Driver Door Disarm Switch Installation Note 1. The driver door disarm switch mark must be positioned towards the harness side of the switch prior to installation. Page 2637 Special Tool(s) Locations Page 8431 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 88 P0110 - P0114: Testing and Inspection P0113 OBD II - Base Gasoline For diagnosis of code P0113 refer to chart P0112-P0147 If there is no link in the chart then: Page 1828 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a message on the vehicle communication network (SCP or HS-CAN). The key features of the PCM-VSO system are to: - Infer vehicle movement from the output shaft sensor signal - Convert transmission output shaft rotational information to vehicle speed information - Compensate for tire size and axle ratio with a programmed calibration variable - Utilize a transfer case sensor for four wheel drive applications - Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer data message via the vehicle communication network data link. The VSO hard -wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22 Hz per MPH (1.3808 Hz per 1 km/h). Page 8139 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn Driver Page 7758 Impact Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. - The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. - The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Page 8219 6 Tighten the bolts. 7 Install the bolt plug cover. 10. If the sliding door to quarter panel does not meet specifications or if the door requires horizontal or vertical adjustment, adjust the sliding door center roller hinge as follows: 1 Remove the center roller hinge nut. 2 Lift the rear of the door to separate the center roller hinge bracket from the center roller hinge mount bracket. 3 CAUTION: Do not swing the door open more than twenty-five degrees or damage to the other hinges may occur. Swing the door open and support if necessary. 4 Mark the edges of the center roller hinge mount bracket. 5 Slightly loosen the bolts. 6 Re-attach the center roller hinge bracket. 7 Tap the center roller hinge into the correct position. 8 Separate the center roller hinge bracket from the center roller hinge mount bracket and tighten the bolts. 9 Re-attach the center roller hinge bracket to the center roller hinge mount bracket. 10 Install the nut. 11 Close the door and check the alignment. 11. NOTE: - The B-pillar and C-pillar wire strikers should be centered after steps nine and ten. For further adjustments, refer to steps three and four. - Make sure the screws are loosened. Adjust the upper and lower wedges. 1 Close the sliding door. 2 Open the sliding door. Page 9390 Parking Lamp: 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. 92-1 Page 1300 P1710 - P1714: Testing and Inspection P1714 4R70W For diagnosis of code P1714 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 1640 Page 6363 Page 3103 Note: The bussed electrical center is located in the engine compartment. Page 9087 Parking Assist Warning Indicator: Service and Repair Rear Parking Aid Speaker PARKING AID SPEAKER - REAR REMOVAL 1. Remove the RH D-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2644 striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the driver seat. 5. NOTE: - The manual seat track seat position sensor is shown, the power seat track position sensor is similar. - Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. P1112 P1110 - P1114: Testing and Inspection P1112 For diagnosis of code P1112 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT The fuel level input (FLI) is a hard wire signal input to the PCM from the fuel pump (FP) module. Refer to the description of the FLI in the On-Board Diagnostics II Monitors. Page 7947 Brake Pressure Switch Page 6278 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Page 8669 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 6237 Note: The bussed electrical center is located in the engine compartment. Page 6857 Accumulator HVAC: Description and Operation SUCTION ACCUMULATOR NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The suction accumulator is mounted near the RH shock tower. The evaporator outlet line attaches directly to the inlet of the suction accumulator and the compressor manifold and tube assembly attaches to the suction accumulator outlet. After entering the inlet of the suction accumulator, the heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return inlet to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. Page 3809 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Specifications Timing Chain Tensioner: Specifications Timing chain tensioner ........................................................................................................................ ....................................................... 11 Nm (8 ft. lbs.) Locations View 151-10 Page 9667 Page 3853 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 5695 Symbols Part 5 Page 4112 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Page 8155 Symbols Part 4 Page 5025 Item 6: Spark Plug Wire-to-Spark Plug Removal Note 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 5548 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. For module configuration and calibration, refer to Module Communications Network. 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU). 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 20 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3428 5. Install the timing chain, crankshaft gear and camshaft gear as an assembly. 6. Make sure that the timing marks and the keyways are aligned. 7. Remove the retaining pin. 8. Install the synchronizer drive gear. Items 16-10: Engine Front Cover Installation Note 1. CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage. CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage. Locations View 151-6 Page 8197 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 7621 Seat Belt: Technician Safety Information WARNING: - Do not bleach or re-dye the webbing, as the webbing may weaken. - All safety belt assemblies include retractors, buckles, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjuster, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected. New safety belt assemblies should be installed if either damage or incorrect operation is noted. - The safety belt buckle pretensioner/safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - After deployment, the air bag surface could contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an accidental deployment. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the safety belt pretensioner is deployed, hearing protection is required. - Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. Page 7815 2. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 17: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 18: Electrical Connector Removal Note 1. Disconnect the occupant classification sensor and remove any retainers from its wiring harness. Item 21: Occupant Classification Sensor (OCS) Removal Note Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Purging Special Tool(s) CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result. The condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. Failure to follow these instructions may result in personal injury. 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 pump reservoir cap. Check the fluid. 2. Raise the front wheels off the floor. 3. Tightly insert the stopper of the vacuum pump into the reservoir. 4. Start the engine. 5. Install the vacuum pump and maintain maximum vacuum, 68-85 Kpa (20-25 in-Hg). 6. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop to stop 10 times. 7. Stop the engine. 8. Release the vacuum and remove the vacuum pump. 9. CAUTION: Do not overfill the reservoir. Fill the reservoir. ^ Use approved transmission fluid. 10. Start the engine. 11. Reinstall the vacuum pump. Apply and maintain maximum vacuum, 68-85 Kpa (20-25 Hg). 12. CAUTION: Do not hold the steering wheel against the stops for more than 3 to 5 seconds at a time. Damage to the power steering pump can occur. Cycle the steering wheel fully from stop to stop 10 times. 13. Stop the engine, release the vacuum, and remove the vacuum pump. 14. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and install the reservoir cap. 15. Visually inspect the power steering system for leaks. 16. Lower the vehicle. 17. CAUTION: Do not overfill the reservoir. Fill the reservoir as needed and visually inspect the power steering system for leaks. Specifications Drive Belt: Specifications Component Location Page 6211 Page 4755 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 2614 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 9538 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 Page 8105 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 1327 P1740 - P1744: Testing and Inspection P1744 Torqshift For diagnosis of code P1744 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6419 Page 2262 Trailer Tow Relay, Right Turn Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn Description and Operation Audible Warning Device: Description and Operation Safety Belt Warning Chime The safety belt warning chime is activated when the ignition switch is in the RUN position and the restraint control module (RCM) detects an unbuckled driver or front passenger safety belt. The instrument cluster generates the chime. The duration of the chime is 6 seconds or until the safety belt is buckled. Belt Minder NOTE: The belt minder feature is configurable. To configure without using a diagnostic tool, refer to Belt Minder Deactivating/Activating. The belt minder feature supplements the current safety belt warning function. The belt minder feature is enabled after the current safety belt warning is complete. The belt minder reminds the driver or front passenger that their safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster once the vehicle speed has exceeded 3 mph (5 km/h). While activated, the belt minder alternates the chime and indicator from ON for 6 seconds to OFF for 30 seconds. The belt minder feature stops when: the driver safety belt is buckled. - the passenger safety belt is buckled (if seat is occupied). - the ignition is turned to OFF or ACC. - 5 minutes have elapsed since belt minder has started. Air Bag Warning Chime The air bag warning chime is activated when the air bag warning lamp is inoperative and an active fault is detected by the RCM. The air bag warning chime sounds after the ignition switch has been in the RUN position for more than 20 seconds. When these conditions exist, the RCM sends a chime request through the air bag warning chime request circuit to the instrument cluster. The instrument cluster will activate the air bag warning chime. The warning consists of 5 sets of 5 1-second tone bursts. Each set is separated by 5 seconds of silence. The warning is repeated every 30 minutes. Key-In-Ignition Warning Chime When the key-in-ignition switch closes, it grounds an input to the instrument cluster, which then sounds a warning chime, provided that the ignition switch is off and the driver door is open. The instrument cluster will sound a steady tone, which will continue until the key is removed, the ignition switch is rotated to the RUN position, or the driver door is closed. Headlamps On Warning Chime The headlamp chime is activated when the instrument cluster receives the headlamps ON signal from the SJB, the key is out of the ignition, and the driver door is ajar. The warning consists of repeated one-half second bursts and will continue to sound until the headlamps/parking lamps are turned off, the driver door is closed, or 10 minutes have elapsed, at which time the battery saver will turn the headlamps off. Message Center Warning Chime The message center warning chime will accompany any initial warning message display, as well as any repeated initial warning message. As the message center is an integral part of the instrument cluster, the interaction between the message center and the chime function is also integral to the instrument cluster. The message center switch tone sounds when any switch on the message center is pressed. The message center switches are supplied with a 5-volt reference signal from the instrument cluster. When a switch is pressed, it completes a circuit through a specific resistor in the switch assembly and back to the instrument cluster. The instrument cluster determines that a switch has been pressed when a voltage is returned to it. Turn Signal Warning Chime The turn signal warning chime sounds when the vehicle is driven in excess of 1/2 mile (0.805 km) with the right or left turn signal active continuously. The instrument cluster receives distance traveled information from the ABS module over the SCP communication network and receives turn signal activity information from the multifunction switch. Page 6166 ABS - Module Replacement Service Tip Yaw Rate Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 1274 P1700 - P1704: Testing and Inspection P1703 For diagnosis of code P1703 refer to chart P1641-P2106 NOTE 15: REFER to Exterior Lighting component testing in Lighting and Horns for further diagnosis of the lighting control module LCM system. Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Lighting and Horns Diagrams Page 5327 13. Remove the special tools. 14. Remove the special tool. (rear of engine compartment) 15. Remove the special tool. (front of engine compartment) Page 7626 striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. When servicing the safety belt buckle pretensioner, deactivate the supplemental restraint system. 3. When servicing the safety belt buckle pretensioner, remove the affected seat from the vehicle. Page 5803 Brake Rotor/Disc: Specifications Brake Rotor/Disc Specifications Front Brake disc minimum thickness .................................................................................................................................................... 28.4 mm (1.11 inch) Minimum thickness to machine front brake disc ......................................................................................................................... 29.0 mm (1.14 inch) Rear Brake disc minimum thickness .................................................................................................................................................... 18.4 mm (0.72 inch) Minimum thickness to machine rear brake disc ........................................................................................................................... 19.0 mm (0.74 inch) Page 3672 4-cylinder engine, so only the Bank 1 HO2S(s) will be utilized. Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable 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 475 to 575°F (246 to 301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency (Figure 123). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. Exhaust System Page 529 P0460 - P0464: Testing and Inspection P0461 For diagnosis of code P0461 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3563 Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 6104 Note: The bussed electrical center is located in the engine compartment. P0985 P0985 - P0989: Testing and Inspection P0985 For diagnosis of code P0985 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 683 P0720 - P0724: Testing and Inspection Automatic Transmission Torqshift For diagnosis of code P0720 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 9613 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042405A Repair Grid Lines (Includes 0.7 Hr. Time To Diagnose And Recheck) 042405B Replace Terminal (Includes 0.4 Hr. Time To Diagnose And Recheck) 042405C Repair Grid Lines And 0.8 Hr. Replace Terminal (Includes Time To Diagnose And Recheck) DEALER CODING CONDITION BASIC PART NO. CODE 7042006 28 Disclaimer Page 52 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4357 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 5845 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 9204 90-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 1653 Page 3636 Page 9343 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 1024 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6336 Note: The bussed electrical center is located in the engine compartment. Page 2434 Page 5159 ^ Windstar, Freestar, Monterey, Taurus, and Sable with column shifter - Must face to the right rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 1) ^ Taurus and Sable with floor shifter - Must face to the rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 2) 10. Install one end of a 24" (61 cm) long piece of 5/16" (8 mm) vacuum hose to the 90° vent stem and secure with a small hose clamp. 11. Route the vacuum hose back and up to the cowl area and down next to the brake master cylinder. Carefully tie rap the hose in place next to the brake master cylinder (do not tie rap to brake lines), be sure the end of the hose is facing down and not directly above anything hot. Page 840 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9212 Test F3-F5 Page 3411 1. Install the timing chain tensioner and bolts. 2. If necessary, retract the tensioner pad retracting mechanism and insert a retaining pin. 3. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position. 4. Turn the camshaft gear so that the timing mark is on the bottom of the balance shaft. Page 1483 P0603-P2198 / U0309-U2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and P1380 P1380 - P1384: Testing and Inspection P1380 For diagnosis of code P1380 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8622 View 151-17 ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 2422 View 151-5 Page 6404 Page 919 P1120 - P1124: Testing and Inspection P1124 For diagnosis of code P1124 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 771 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2763 Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Start the engine and recenter the steering wheel. ^ Recheck the toe settings and adjust if necessary. Component Locations Page 878 P0985 - P0989: Testing and Inspection P0988 For diagnosis of code P0988 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Service and Repair Hood Latch: Service and Repair HOOD LATCH REMOVAL Page 63 P0100 - P0104: Testing and Inspection P0103 For diagnosis of code P0103 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 2194 Cruise Control Switch: Service and Repair Without Remote Audio Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9770 Wiper Motor: Service Precautions CAUTION: Do not handle the windshield wiper motor abusively when diagnosing the wiper operations. Failure to follow this caution may result in damage to the motor magnets and will make the windshield wiper motor inoperative. Rough handling of new windshield wiper motors may also damage the motor magnets. Page 8039 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the RH quarter trim panel. NOTE: Rear parking aid module shown, front and rear parking aid module similar. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9385 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. Page 8419 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 8519 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) REMOVAL 1. CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery. 2. Remove the driver seat. 3. Remove the parts in the order indicated in the illustration and table. Page 6754 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Page 7086 Heater Core Case: Description and Operation HEATER CORE AND EVAPORATOR CORE HOUSING The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Page 3308 Symptom Chart Page 4335 which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Electronic Throttle Control System Strategy GEN II ETC System As stated earlier the torque based ETC strategy was developed mainly to improve fuel economy and to accommodate Variable Cam Timing. This is possible by not coupling the throttle angle to the drivers pedal position. By uncoupling the throttle angle (produce engine torque) from pedal position (driver demand). This allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. ETC is used on the 2004 MY Lincoln LS and Ford Thunderbird, Explorer/Mountaineer, and the new light-duty F-series. Page 3643 Page 1918 The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 2: Utility Compartment Removal Note Engine Related Diagnosis P1570 - P1574: Testing and Inspection Engine Related Diagnosis For diagnosis of code P1572 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1751 Page 384 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4188 14-3 Page 6047 Part 2 2. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Negative Ground Cable Bolt Removal Note 1. Remove the pin-type retainers and the radiator sight shield to access the negative ground cable bolt. Item 16: Generator B+ Cable Nut Removal Note 1. Position the cable boot aside to access the nut. INSTALLATION 1. To install, reverse the removal procedure. Page 4383 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 123 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2983 1. Verify that the valves on the deluxe injector loop kit are closed. 2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves. 4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine. Start the engine. 5. Open the high-pressure service valve. 6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system. Page 7545 Locations View 151-15 Page 3086 Page 5208 ^ Windstar Freestar and Monterey (Figure 3, 4, and 5) Taurus and Sable with column shifter (Figure 6) Page 1764 which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Electronic Throttle Control System Strategy GEN II ETC System As stated earlier the torque based ETC strategy was developed mainly to improve fuel economy and to accommodate Variable Cam Timing. This is possible by not coupling the throttle angle to the drivers pedal position. By uncoupling the throttle angle (produce engine torque) from pedal position (driver demand). This allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. ETC is used on the 2004 MY Lincoln LS and Ford Thunderbird, Explorer/Mountaineer, and the new light-duty F-series. Page 6249 Page 3682 Torque Sequence LH 1. Tighten the exhaust manifold nuts in the sequence shown. Item 2: EGR Tube-to-Exhaust Manifold Nut Installation Note 1. Connect the EGR tube to the exhaust manifold. Page 6577 Rotate the front wheel spindle tie-rods. 7. Tighten the nuts. 8. Install the clamps. 9. Start the engine and recenter the steering wheel. ^ Recheck the toe settings and adjust if necessary. Page 1110 P1385 - P1389: Testing and Inspection P1388 For diagnosis of code P1388 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 361 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6678 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 591 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL REMOVAL NOTE: RH side is shown. LH side is similar. 1. Remove the parts in the order listed in the illustration and table. Page 7156 Page 8995 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 3429 Clean and inspect the engine block and front cover as follows: - Pack the exposed portion of the oil pan with clean shop towels. - Plug the oil and coolant passages. - Clean the gasket surfaces. - Clean all surfaces requiring gasket sealant with metal surface cleaner. - Using compressed air, remove any remaining foreign material from the engine block and front cover. - Remove the shop towels from the oil pan. - Remove the plugs or seals from the oil and coolant passages. 2. Apply a small amount of silicone gasket and sealant as shown. 3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown. Timing Cover Torque Sequence 4. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence. NOTE: Use pipe sealant with tenon on studs No. 4, 6 and bolt No. 12. Install the engine front cover with the engine front cover studs in their original locations. Page 1237 Inspection Page 3606 Part 3 3. Remove the parts in the order indicated in the illustrations and tables. Item 6: Storage Console Removal Note 1. Disconnect the electrical connector. Item 7: Upper Instrument Panel Finish Panel Removal Note 1. Disconnect the electrical connector. Item 8: Instrument Panel Bolt Removal Note Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Page 8177 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 6360 Smart Junction Box (SJB) Page 7164 View 151-11 Page 1459 P2125 - P2129: Testing and Inspection P2127 For diagnosis of code P2127 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4206 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 4306 View 151-6 Page 8509 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 8943 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 692 4R70W For diagnosis of code P0722 refer to chart Part 3 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0722 refer to chart Seat Adjust Switch, Passenger Side Front Page 3781 Page 9692 2. Remove the parts in the order indicated in the illustration and table. Item 1: Sliding Door Window Glass Removal Note WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. 1. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. Page 5610 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 8391 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Locations View 151-11 Page 8826 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 6447 Note: The bussed electrical center is located in the engine compartment. Page 1609 View 151-14 Page 7033 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting AIR CONDITIONING LINE (PEANUT) FITTING DISCONNECT 1. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. Remove the nut and separate the two halves of the peanut fitting. 2. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring seal groove, resulting in refrigerant leaks. Remove the O-ring seal with a non-metallic tool. CONNECT 1. Clean all dirt or foreign material from the fittings. 2. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Install the O-ring seal. Lubricate the O-ring seal with mineral oil. 3. Lubricate the inside of the fittings with mineral oil. Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: Recalls Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Auxiliary Blower Motor Relay Page 3621 Special Tool(s) Page 7955 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green vacuum fluorescent, fixed format display. The message center display is integral to the instrument cluster. The message center is controlled by the 3 message center switches (INFO, SETUP and RESET). PRINCIPLES OF OPERATION Message Center The message center is an integral part of the instrument cluster. The message center communicates with the PCM, SJB, and ABS/TC/stability assist module over the SCP network. Display Information The display modes are: information - setup - system check - warning - temporary alert The message center information can be selected by pressing any of the following buttons: SELECT - RESET - ENGLISH/METRIC The select display and the reset display will time-out and default to the information display mode. The temporary alert display will interrupt the current display to show the status of an event that has just happened. The warning display interrupts the current display until cleared or reset by the driver. Information Displays The information displays are as follows: odometer mileage - distance to empty - trip odometer - average fuel economy - trip elapsed drive time - upper 2 lines off, lower line on Setup Displays The setup displays are timed modes and default back to the information display function. The setup display modes are: - language - English/metric units - system check System Check The system check display is a sub-routine of the setup menu. They are timed modes that terminate after a finite interval, then default back to the information display function. The system check display modes are: oil life XXX% (configurable) - charging system - washer fluid level - brake fluid level - door ajar - exterior lamp status - traction control - low tire pressure - fuel level - miles to empty Warning Messages The warning messages can interrupt the display until cleared or reset by the driver. The warning messages are single cycle, non-resettable and repetitive warning messages. The single cycle warning messages will display once whenever the key is turned to ON or a fault occurs in a system and can be cleared by pressing the RESET button. Once cleared, the messages are not displayed again until the next ignition cycle except CHECK TIRES and TURN SIGNAL ON, both of which are displayed again if a fault condition re-occurs. The single cycle warning messages are: Page 3655 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Power Window Switch, RH Side Front View 151-19 Page 8658 1. Remove the screws and pin-type retainers, and remove the latch covers (one shown). 2. Release the J-clips. 3. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat backrest foam pad. Separate the hook-and-loop fasteners. 4. Remove and discard all the hog rings and remove the cushion trim cover. Item 16: Cushion Latch Cables Disassembly Note 1. Release the cables and route handle through seat pan. 2. Release the cable from seat pan clips (one shown). Page 7822 Special Tool(s) Page 9585 Page 1831 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Removal and Installation POWERTRAIN CONTROL MODULE (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6872 View 151-9 Page 4831 1. Using the special tool, remove the fuel pump module lock ring. Item 20: Fuel Pump Module Removal Note 1. CAUTION: - The fuel pump module must be handled carefully to avoid damage to the float arm and filter. - Some fuel will remain in the fuel pump module after draining the fuel tank. Carefully drain the fuel pump module into a suitable container. Remove the fuel pump module and position aside. Item 21: Fuel Pump Module Gasket Removal Note 1. NOTE: Be careful that no foreign material or debris falls into the tank. Upon removing the fuel pump module gasket make sure the mounting area is clean and free of debris. Item 22: Fuel Gauge Sending Unit Removal Note 1. NOTE: Note the routing of the sending unit wire for installation. Unwrap the sending unit wire from the rest of the fuel pump module wire harness. 2. Remove the heat shrink tube covering the electrical connector. Page 1432 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Quarter Window Glass: Service and Repair REAR QUARTER WINDOW GLASS REMOVAL 1. Remove the rear quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. Item 3: Rear Quarter Window Glass Assembly Removal Note 1. If removing the left quarter window glass, remove the rear A/C. 1 Remove the pin-type retainers. 2 Remove the upper A/C duct. Page 8195 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 3782 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) REMOVAL 1. Remove the LH lower B-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7096 Heater Hose: Description and Operation UNDERBODY HEATER LINES The underbody auxiliary heater lines have the following features: - The underbody auxiliary heater inlet line is a aluminum tube assembly that carries coolant from the engine coolant supply line to the auxiliary heater core inlet. - The underbody auxiliary heater outlet line carries coolant from the auxiliary heater core to the front heater core outlet line. Diagrams Timing Chain: Diagrams Page 3518 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Item 6: Spark Plug Wire-to-Spark Plug Removal Note Diagrams Page 690 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift For diagnosis of code P0722 refer to chart Page 1893 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 8117 Trailer Lamps: Pinpoint Tests BEC C1035a SJB C2280c Page 961 Inspection Diagrams Page 5674 Brake Bleeding: Service and Repair Brake System Bleeding Special Tool(s) Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the diagnostic tool cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool instructions. 2. Clean all the dirt from the area and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 9030 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module (Figure 71),(Figure 72) and(Figure 73) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 9387 Parking Lamp: Connector Views Page 4706 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 1479 P2195 - P2199: Testing and Inspection P2197 OBD II - Base Gasoline For diagnosis of code P2197 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P2197 refer to chart Page 7003 Condenser HVAC: Testing and Inspection EVAPORATOR/CONDENSER CORE - ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect evaporator core or condenser core from the A/C system. 3. Clean the manifold fittings. 4. Connect the appropriate test fittings from the A/C Fittings Set to the condenser or evaporator core tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter that will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45-minuteevacuation is necessary to remove any refrigerant from oil left in the evaporator core or condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new evaporator core or condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. 9. If the evaporator core or condenser core does leak, as verified by the above procedure, install a new evaporator core or condenser core. Page 4253 View 151-4 Locations View 151-6 Page 4485 Fuel Pressure Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Locations Page 1750 Page 3744 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 2072 Page 8336 14. Reconnect the 2 rear window defrost electrical connectors. Page 2595 Bussed Electrical Center (BEC) Fuse: Locations Bussed Electrical Center (BEC) Page 8283 View 151-21 Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Page 159 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8857 Cruise Control Servo: Service and Repair SPEED CONTROL ACTUATOR REMOVAL 1. Remove the air cleaner assembly. 2. Remove the parts in the order indicated in the illustration and table. Item 2: Speed Control Cable Removal Note 1. Rotate the speed control cable cap counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Page 514 Inspection Page 1555 Page 4996 Page 8990 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 8827 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 121 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1133 Inspection Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 5319 7. Remove the passenger compartment air intake box. 8. Remove the air intake tube. 9. Remove the front upper radiator shield. 10. Remove the hood latch and position aside. Page 6170 Page 7564 Page 6901 Powertrain Control Module (PCM) Reset Engine Control Module: Service and Repair Powertrain Control Module (PCM) Reset POWERTRAIN CONTROL MODULE (PCM) RESET Description All OBD II scan tools support the powertrain control module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. For more information about a drive cycle, refer to Drive Cycles. See: Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Drive Cycles The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. Resetting Keep Alive Memory (KAM) Resetting Keep Alive Memory will return PCM memory to its default setting. Adaptive learning contents such as idle speed, refueling event, and fuel trim are included. A PCM Reset (described above) is also part of a KAM Reset. Both can be useful in post repair retest. After Keep Alive Memory has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. This function may not be supported by all scan tools. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Page 3432 Item 5: Oil Filter Installation Note 1. Tighten oil filter one half turn after gasket makes contact with oil filter housing. System Diagnosis P1465 - P1469: Testing and Inspection For diagnosis of code P1469 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7807 With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. Item 1: Seat Cushion Pan Installation Note 1. Bend the retaining ear back on the pressure sensor component bracket. Item 2: Bladder, Occupant Classification Sensor (OCS) Installation Note 1. CAUTION: - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Page 5472 Page 269 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1345 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8424 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 6163 Page 1023 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1264 refer to chart Page 6117 Fuse Block: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 7177 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 2 Page 8919 3. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 1: Instrument Panel Center Trim Panel Removal Note 1. Pull out to release the retaining clips. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 714 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0740 refer to chart Page 7243 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION WARNING: All safety belt assemblies including retractors, buckles, front safety belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjuster, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. New safety belt assemblies should be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected for damage or incorrect operation and new assemblies installed if a problem is found. Failure to follow these instructions may result in personal injury. 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). Carry-out the Functional Test. See: Seat Belt Systems/Testing and Inspection/Component Tests and General Diagnostics Page 3678 Exhaust Manifold: Description and Operation 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. Page 6486 Page 2672 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 709 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7129 Special Tool(s), Part 2 SPECIAL TOOL(S) Fluorescent Dye Detection NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line, and fitting in the refrigerant system for a leak. 1. Check for leaks using a Rotunda approved UV lamp. - Inspect all components, lines, and fittings of the refrigerant system. 2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent. 6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda approved UV lamp. Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda Page 8592 INSTALLATION 1. To install, reverse the removal procedure. Item 3: Driver Seat Module (DSM) Installation Note 1. Once the DSM is installed, it is necessary to download the module configuration information from the diagnostic tool into the new module. Locations View 151-16 Page 2499 Fuel Temperature Sensor: Description and Operation ENGINE FUEL TEMPERATURE SENSOR Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 6622 18. Install the reservoir cap. Page 2984 7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating. Close the valves on the deluxe injector loop kit. 9. NOTE: Leave all valves on the special tool closed when not in use. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle. Page 226 P0180 - P0184: Testing and Inspection P0183 OBD II - Base Gasoline For diagnosis of code P0183 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1256 P1640 - P1644: Testing and Inspection P1641 For diagnosis of code P1641 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7035 Remover, Refrigerant Coupling Spring Page 122 P0125 - P0129: Testing and Inspection P0128 For diagnosis of code P0128 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Initial Inspection and Diagnostic Overview Drive/Propeller Shafts, Bearings and Joints: Initial Inspection and Diagnostic Overview Driveline System Inspection and Verification Halfshafts NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. Inspect the boots for evidence of cracks, tears, or splits. Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Page 8659 ASSEMBLY 1. To assemble, reverse the disassembly procedure. Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Page 3607 1. Install a long bolt or threaded rod with the same diameter and thread pitch, in place of the LH instrument panel bolt, to support the instrument panel while allowing it to be moved away from the dash panel. Item 9: Instrument Panel Bolt Removal Note 1. Install a long bolt or threaded rod with the same diameter and thread pitch, in place of the LH instrument panel bolt, to support the instrument panel while allowing it to be moved away from the dash panel. Item 12: Instrument Panel Support Brace Bolt Removal Note 1. Remove the bolts and the center instrument panel support brace. Item 14: Instrument Panel Bolt Removal Note 1. Loosen the RH instrument panel bolts one half of the bolt length, but do not completely remove the bolts. Item 15: Instrument Panel Removal Note 1. Working through the glove compartment opening, remove the bolt. 2. Position the left side of the instrument panel 3 inches away from the dash panel. Item 22: Wire Harness Removal Note 1. Detach the wire harness from the heater core cover. INSTALLATION 1. To install, reverse the removal procedure. 2. Fill the engine cooling system. Locations Page 6337 Page 3228 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Items 1-3: Rocker Arm Removal Note 1. If the rocker arms are to be reused, they must be installed in their original location. Mark the rocker arms for location before removing. 2. If removing valve springs, rotate the crankshaft until the piston is at the top of its stroke with both the intake and exhaust valves closed prior to removing the rocker arm. Item 7: Valve Tappet Removal Note Accessory Delay Relay 1 Page 7470 4. WARNING: Do not separate components. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): - select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Page 644 P0705 - P0709: Testing and Inspection P0706 For diagnosis of code P0706 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - A/T - 4F50N No 1-2 Upshift/DTC P0732 Set Clutch: All Technical Service Bulletins A/T - 4F50N No 1-2 Upshift/DTC P0732 Set TSB 04-17-10 09/06/04 4F50N TRANSAXLE NO 1-2 UPSHIFT AND DTC P0732 FORD: 2004-2005 Taurus, Freestar MERCURY: 2004-2005 Sable, Monterey This article supersedes TSB 04-15-12 to update the vehicle model years. ISSUE Some 2004-2005 Taurus/Sable and Freestar/Monterey vehicles, may exhibit a diagnostic trouble code (DTC) P0732 and a no 1-2 upshift condition. This may be due to an intermediate clutch piston seal becoming torn or loose (de-bonded) from the piston. ACTION To service, perform normal diagnosis per Workshop Manual. If the cause is determined to be internal to the transaxle, inspect the intermediate clutch piston seal. The outer clutch seal is bonded to the piston. If the seal is torn or loose replace the piston. Inspect the intermediate clutch plates and replace if necessary. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7E005 D8 Disclaimer Page 519 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442-P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3269 Part 2 Of 2 1. Disconnect the RH front anti-lock brake wheel sensor electrical connector. 2. Position a safety stand under the RH side of the subframe. Page 1044 Inspection Page 8103 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 6902 Page 9224 Brake Light Switch: Service and Repair STOPLAMP SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 1205 Inspection Page 80 P0105 - P0109: Testing and Inspection P0109 For diagnosis of code P0109 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 2222 P1115 P1115 - P1119: Testing and Inspection P1115 For diagnosis of code P1115 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7162 Service Precautions Windshield: Service Precautions CAUTION: - Cover the instrument panel in order to prevent possible damage. - Care must be used to avoid scratching the pinch weld. - If equipped, care must be taken to avoid damage to the headliner wiring harness. - After installing the new windshield glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. - Care must be taken to avoid scratching the pinch weld. - All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM-recommended curing automotive paint primer and allow to cure. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. - Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. Page 9345 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Specifications Axle Nut: Specifications Note: Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut Axle nut ................................................................................................................................................ ................................................... 130 Nm (96 ft.lbs.) Page 3580 Part 2 Of 2 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 7: Radiator Alignment Pins Removal Note 1. Tie the radiator and the condenser to the upper radiator support using mechanics wire. ^ Allow 2 inches of slack in the condenser wire to allow for movement. ^ Remove the radiator alignment pins. Item 13: Transmission Cooler Tubes Removal Note Page 3422 Part 3 Of 3 To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. P1180 P1180 - P1184: Testing and Inspection P1180 For diagnosis of code P1180 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 5262 4. Remove the screws and the instrument panel opening reinforcement cover. 5. Remove the transmission selector cable. 1 Disconnect the transmission selector cable end from the steering column. 2 Push the lock tab and separate the transmission selector cable from the bracket. 3 Remove the transmission selector cable from the vehicle. Item 1: Transmission Selector Cable End Installation Note 1. Verify that the engine will start in PARK and NEUTRAL and that the reverse lamps illuminate in REVERSE. If not, the transmission selector cable will need to be adjusted. For additional information, refer to Selector Lever Cable Adjustment. See: Adjustments/Selector Lever Cable Adjustment Page 240 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0192 refer to chart Page 8438 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. Description and Operation Air Diverter Solenoid: Description and Operation AIR BYPASS SOLENOID Secondary Air Injection Bypass Solenoid The secondary air injection bypass (AIR bypass) solenoid (Figure 113) is used by the PCM to control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit vacuum release. Locations View 151-10 Page 441 P0350 - P0354: Testing and Inspection P0353 For diagnosis of code P0353 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7423 Impact Sensor: Vehicle Damage Warnings CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. Page 325 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2344 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Service and Repair Cruise Control Servo Cable: Service and Repair SPEED CONTROL CABLE REMOVAL 1. Remove the air cleaner assembly. 2. Remove the parts in the order indicated in the illustration and table. Item 3: Speed Control Cable Removal Note 1. Remove the speed control cable cap. 1 Press the locking tab. Page 4478 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Page 6086 Page 5687 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Heated Oxygen Sensor (HO2S) #22 Page 8869 Cruise Control Switch: Service and Repair Without Remote Audio Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Material Material 1. Remove the radiator and cooling fan assembly. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Page 1127 Inspection Page 7429 Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. Remove the front seat on the side with the affected side impact sensor. 4. Position the carpet aside to access the front row side impact sensor. 5. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 5271 Item 2: Lower Steering Column Shroud Removal Note 1. Remove the three screws and remove the lower steering column shroud. Item 5: Shift Lever Retaining Pin Installation Note 1. ZCAUTION: Never reinstall the old gearshift retaining pin. Damage to the lever will occur. Install the gearshift lever and install a new pin. Page 962 P1155 - P1159: Testing and Inspection P1158 For diagnosis of code P1158 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2389 Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. Page 1922 Air Bag Control Module: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Page 3010 Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Page 745 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2105 P1150 P1150 - P1154: Testing and Inspection P1150 For diagnosis of code P1150 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Locations View 151-5 Page 2403 Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two design types of IAT sensors used, a stand alone\non-integrated type (Figure 39) and a integrated (Figure 40) 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. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A non-integrated screw in type (Figure 39) and an integrated type, which is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 48). The TMAP sensor consists of a IAT thermistor and a manifold absolute pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation found later. Page 1758 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. P0442 P0440 - P0444: Testing and Inspection P0442 For diagnosis of code P0442 refer to the system experiencing the problem. Computers and Control Systems P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5413 Torque Specifications Page 7021 Page 513 P0450 - P0454: Testing and Inspection P0454 For diagnosis of code P0454 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1310 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1718 refer to chart Page 1626 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 2 Page 3093 Note: The bussed electrical center is located in the engine compartment. Page 5689 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 2217 Blower Motor Switch: Description and Operation Electronic Automatic Temperature Control BLOWER MOTOR SPEED CONTROL The blower speed control: - is located on the heater core and evaporator core housing near the blower motor. - PWM signals from the EATC module to control a high-current, variable ground feed for the blower motor. - varies the blower motor speed and is controlled by the EATC module software. - has a delay function to provide a gradual increase or decrease in blower motor speed under all conditions. Page 1843 Page 4694 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 2183 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied/Brake Deactivator Switch BRAKE PRESSURE APPLIED/BRAKE DEACTIVATOR SWITCH The brake pressure applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, which supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Page 1558 Page 2623 personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 2. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining ear. 3. CAUTION: Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Align the bladder to the seat cushion pan. Item 5: Electronic Control Unit (ECU) Installation Note 1. Slide the electronic control unit (ECU) into the seat cushion pan bracket and install the rivets. - The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). Item 8: Seat Cushion Trim Cover Installation Note 1. CAUTION: - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. Item 9: Seat Cushion Foam Pad Installation Note 1. CAUTION: Inspect the seat cushion pad and pan for any foreign objects before installing the seat cushion pad to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad to the seat cushion pan and set in place. 2. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the Page 3825 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer P0190 P0190 - P0194: Testing and Inspection P0190 For diagnosis of code P0190 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-10 Page 6733 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Page 8287 Locations View 151-18 System Diagnosis P1730 - P1734: Testing and Inspection For diagnosis of code P1731 refer to chart P0731-P1760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 440 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-14 P0180 P0180 - P0184: Testing and Inspection P0180 For diagnosis of code P0180 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 658 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0712 refer to chart Page 6785 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. Item 3: Shock Absorber and Spring Assembly Removal Note 1. CAUTION: Do not allow the axle shaft to move outboard. Over-extension of the tripod CV joint can result in separation of internal parts, causing failure of the axle shaft. Push down on the front wheel knuckle until the strut and spring assembly is free of the front wheel knuckle. Support the front wheel knuckle to prevent the front axle shaft from moving outboard. 2. For additional information on the disassembly and assembly of the shock absorber and spring assembly, refer to Shock Absorber and Spring Assembly. Item 3: Shock Absorber and Spring Assembly Installation Note 1. Check the front end alignment and adjust as necessary. Temperature Blend Door Actuator, Driver View 151-9 Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the rear window wiper and motor. 2. Remove the parts in the order indicated in the illustration and table. Item 1: Liftgate Window Glass Removal Note 1. Remove the rear wiper motor. Page 5170 Page 1416 P2065 - P2069: Testing and Inspection P2068 For diagnosis of code P2068 refer to NOTE 7: NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9775 Wiper Switch: Diagrams Page 8110 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. Page 1747 Page 7333 Page 549 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Forward Crash Sensor Page 3487 Ignition Cable: Service and Repair Customers have reported success using the following spark plug wire placement on the coil pack." IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 4313 Page 8948 Page 8648 Seat Cushion: Service and Repair Rear Seat Cushion Bench Seat, Second Row REAR SEAT CUSHION - BENCH SEAT, SECOND ROW DISASSEMBLY 1. Seat with optional cupholder shown, without cupholder similar. 2. Remove the bench seat, second row. Page 3550 Radiator Cooling Fan Motor: Description and Operation FAN CONTROL Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (Negative Duty Cycle) LS6/LS8, Thunderbird: FCV Duty Cycle Output From PCM The PCM monitors certain parameters (such as engine coolant temperature, vehicle speed, A/C on/off status, A/C pressure, etc) 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). For Relay Controlled Fans: The PCM controls the fan operation through the Fan Control (FC) (single speed fan applications), Low Fan Control (LFC), Medium Fan Control (MFC) and/or High Fan Control (HFC) outputs. 2.0L Focus (with A/C) And Taurus/Sable: PCM FC Output State For Cooling Fan Speeds Chart Page 8754 Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 5943 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Seat Adjust Switch, Passenger Side Front Page 303 Inspection Page 927 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7369 Air Bag Resistor: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. P0116 P0115 - P0119: Testing and Inspection P0116 For diagnosis of code P0116 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Page 332 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7821 6. NOTE: When installing an occupant classification sensor service kit, the main seat wire harness pressure sensor electrical connector does not get used. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. 2 Slide the electronic control unit (ECU) into the seat cushion pan bracket. The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). 3 Install the rivets. 4 Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector. 5 Tie-strap the unused main seat wire harness pressure sensor electrical connector safely out of the way. 6 Tie-strap all loose wire harnesses and electrical connectors safely out of the way. Item 4: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 7: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 8: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Page 6912 Blower Motor Relay: Testing and Inspection Front blower motor relay Locations View 151-13 Page 6694 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 5244 Page 2564 View 151-29 Page 1923 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Page 8427 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 947 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 277 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0205 refer to chart Page 8231 8. Tighten the nut. 9. Cycle the front door window glass to make sure of correct operation. Readjust the height if necessary. 10. Install the front door trim panel and watershield. Page 3501 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 2016 View 151-21 Locations View 151-5 Page 7723 Seat Sensor/Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Page 5558 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 7182 Page 3315 1. Remove the accessory drive belt. - Rotate the accessory drive belt tensioner counterclockwise. - Push the spring clip towards the belt tensioner to lock the accessory drive belt tensioner in place. Item 1: Accessory Drive Belt Installation Note 1. Install the accessory drive belt. - Position the accessory drive belt onto the engine. - Rotate the accessory drive belt tensioner counterclockwise until spring clip releases. Page 9496 Turn Signal Switch: Diagrams Left Front Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 8670 Symbols Part 2 Page 8687 Seat Heater: 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. 119-1 Page 2252 System Diagnosis P0420 - P0424: Testing and Inspection For diagnosis of code P0420 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Never run the engine with one wheel off the ground, such as when changing a tire. The wheel still on the ground could cause the vehicle to move. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to lift the vehicle for any other purpose. Refer to the Owner Literature when using the jack supplied with the vehicle. - Under no circumstances should the vehicle ever be lifted by the front control arms, front I-braces, suspension arm brackets, rear stabilizer or differential housing. Severe damage to the vehicle could result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the following procedure. Jacking Points Jacking Points To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING CAUTION: - Do not allow the lift adapters to contact the steering linkage, suspension arms, front I-braces, stabilizer bar, or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the lift adapters prior to lifting the vehicle. - Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. - Do not lift the vehicle on the rocker panel pinch flange except at the designated lift points or body damage may occur. Lift the vehicle using the following procedure. Lifting Points-Drive-On Hoist Description and Operation EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR VACUUM REGULATOR SOLENOID EVR Solenoid Test Graph EGR Vacuum Regulator Solenoid Data Chart The EGR vacuum regulator solenoid (EVR), (Figure 92) is an electromagnetic device which is used to regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not enough to open the EGR valve. Page 4906 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. C110-C315 Multiple Junction Connector: Diagrams C110-C315 Page 6770 View 151-9 Page 5702 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 7887 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Page 9417 Page 8131 P0217 P0215 - P0219: Testing and Inspection P0217 For diagnosis of code P0217 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8814 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Locations View 151-10 Page 4516 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. Item 2: HO2S and Catalyst Monitor Sensors Removal Note Page 2755 Part 2 Of 2 Rear Ride Height Measurement Part 1 Of 2 Part 2 Of 2 Wheel Track Page 4385 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Diagrams Page 8809 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Entertainment Systems - DVD Player Screen Latch Rattle DVD Player: Customer Interest Entertainment Systems - DVD Player Screen Latch Rattle TSB 04-14-6 07/26/04 RATTLE FROM DVD SCREEN LATCH ASSEMBLY FORD: 2003-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2003-2005 Mountaineer ISSUE Some 2003-2005 Explorer 4drlMountaineerlAviator vehicles equipped with a factory installed DVD player may exhibit a rattling noise coming from the flip down screen latch assembly. ACTION To repair, replace the DVD screen latch assembly. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IT IS NOT NECESSARY TO REMOVE THE DVD ASSEMBLY FROM THE VEHICLE DURING THIS REPAIR. NOTE NO TOOLS ARE REQUIRED FOR THIS REPAIR. 1. Position the DVD screen in the down position. 2. Gently pull the latch out from the bottom of the DVD screen. 3. Install the new latch, making sure that the latch is lined up with the grooves in the body of the screen and gently sliding the latch into place. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041406A Replace The DVD Screen 0.2 Hr. Latch Assembly DEALER CODING CONDITION BASIC PART NO. CODE 10E956 33 Page 7656 Seat Belt Buckle Switch: Description and Operation SAFETY BELT SWITCH As part of the supplemental restraint system (SRS), the driver and passenger safety belt buckles are equipped with hall-effect sensors. The safety belt switches indicate to the restraints control module (RCM) whether the safety belt buckles are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The safety belt switches are also used for the driver safety belt warning system and the driver and passenger belt minder. Refer to Seat Belt Systems. Page 6077 Starter Motor: Service Precautions WARNING: When carrying out maintenance on the starting system be aware that the heavy gauge leads are connected directly to the battery. Make sure the protective caps are in place when maintenance is completed. Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor INTAKE AIR TEMPERATURE SENSOR Typical Stane Alone/Non-integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange Type MAF Sensor The intake air temperature (IAT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Page 4356 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 3182 10. Using special tool 205-343 (T95T-3514-A), secure the 2 inner bellows clamps. 11. Reinstall the steering gear per Section 211-00 of the Workshop Manual. 12. Perform a front wheel alignment. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050908A 2004-2005 2.5 Hrs. Freestar/Monterey Replace One Halfshaft, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) 050908B 2004-2005 2.8 Hrs. Freestar/Monterey Replace Both Halfshafts, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) DEALER CODING CONDITION BASIC PART NO. CODE 3B436 01 Disclaimer ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 6399 Page 5875 Brake Master Cylinder: Service and Repair Brake Master Cylinder and Brake Booster WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Disconnect the battery. 2. Remove the air cleaner assembly. Page 8525 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling Pinpoint Test. NOTE: Refer to Multimeter User's Manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, install a new switch; otherwise, return to the calling Pinpoint Test. Page 8530 Power Mirror Switch: Testing and Inspection Page 3508 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 2930 Attachment I - Administrative Information OASIS ACTIVATED? ^ Ford Freestar - Yes ^ Mercury Monterey - OASIS will be activated 11/04/03 FSA VIN LIST ACTIVATED? ^ Ford Freestar - Yes ^ Mercury Monterey - FSA VIN list will be activated 11/04/03. NOTE: 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 action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Also correct other affected vehicles identified in OASIS which are brought to your dealership. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. ^ 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 ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Page 9346 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 72 P0105 - P0109: Testing and Inspection P0107 OBD II - Base Gasoline For diagnosis of code P0107 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: Page 2634 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. 12. NOTE: When installing a new occupant classification sensor, a prepaid return postcard is provided with the new occupant classification sensor. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company. When returning the inoperative occupant classification sensor, include the following: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only). Item 1: Occupant Classification Sensor (OCS) (For OCS Service Kit) Installation Note 1. Bend the tab back on the pressure sensor component bracket. 2. CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. If equipped with heated seats, make sure the wire harness is accessible after trim cover attachment. Page 5976 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 9475 Headlamp Dimmer Switch: Diagrams Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 6470 Page 7938 Safety Belt System Seat Belt Tension Sensor: Description and Operation Safety Belt System SAFETY BELT TENSION SENSOR The safety belt tension sensor is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is located at the front passenger safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Damaged universal transmitter - Damaged receiver 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. See: Symptom Related Diagnostic Procedures Service Precautions Memory Positioning Module: Service Precautions CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Page 7168 Page 8763 Page 876 P0985 - P0989: Testing and Inspection P0986 For diagnosis of code P0986 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Inspection and Verification 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply: - All of the accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If any of the accessories are damaged, have a worn or damaged bearing, or internal torsional resistance above normal, install a new component as required. - NOTE: If fluids get on the drive belt (including power steering fluid, engine coolant, engine oil or air conditioning system lubricant), clean the drive belt with soap and water and thoroughly rinse with clean water. A new drive belt does not have to be installed if no apparent damage has occurred. NOTE: If the drive belt tensioner arm does not rotate freely without binding, the drive belt tensioner is worn or damaged. If the drive belt is outside the installation wear range window, install a new drive belt. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. 3. Inspect for drive belt cracking/chunking/wear. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. A new drive belt should be installed if chunking occurs. V-Ribbed Serpentine Drive Belt With Cracks Across Rim V-Ribbed Serpentine Drive Belt With Chunks of Rib Missing 4. If the concern(s) remains after inspection, determine the symptoms. See: Symptom Related Diagnostic Procedures Page 3071 Initial Inspection and Diagnostic Overview Brake Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - SCP, ISO or UBP circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for SJB, refer to Information Bus (Module Communications Network). - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the SJB. 7. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Page 3002 4. Fill the dye/lubricant injector with the correct amount of clean 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. Page 5087 Disclaimer Page 9532 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 1496 P2270 - P2274: Testing and Inspection P2272 For diagnosis of code P2272 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7434 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. Page 6913 Page 6396 Page 264 P0200 - P0204: Testing and Inspection P0202 OBD II - Base Gasoline For diagnosis of code P0202 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4709 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 Page 3404 Timing Chain: Service and Repair Engine Front Cover, Timing Gears, Chain and Tensioners Special Tools And Equipment Special Tool(s) Material Material Page 3528 Water Pump: Service and Repair REMOVAL AND INSTALLATION Special Tools And Equipment Special Tool(s) Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the accessory drive belt. Locations View 151-22 Page 1301 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1714 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4180 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 6497 Page 995 Inspection Page 3618 Heater Hose: Service and Repair Removal and Installation AUXILIARY HEATER OUTLET AND INLET LINE REMOVAL 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Clamp off and disconnect the heater hoses at the front of the auxiliary heater inlet and outlet lines. 3. Remove the bolt and the front line bracket. 4. Remove the bolts and the two rear line brackets. Page 4902 View 151-5 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 405 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-6 Page 1733 Note: The bussed electrical center is located in the engine compartment. Page 3120 Power Window Switch, RH Side Front View 151-19 Page 8392 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 4695 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 8305 1. Remove the rivet. Item 14: Rivet Removal Note 1. Remove the interior sliding door handle. - Remove the rivets and slide the interior handle forward. INSTALLATION 1. To install, reverse the removal procedure. Item 14: Rivet Installation Note 1. Using the special tool, install the new rivets. Item 12: Rivet Installation Note Page 6840 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tires are off of the ground. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the wheel and tire assembly. Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire from the front wheel bearings. If movement exists, a new hub and bearing assembly must be installed. Page 5161 ^ Windstar Freestar and Monterey (Figure 3, 4, and 5) Taurus and Sable with column shifter (Figure 6) Page 8478 Page 4420 Disclaimer Removal and Installation Impact Sensor: Service and Repair Removal and Installation Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Locations View 151-10 Page 6796 CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Frame Contact Lift, Single-Post Lift, Two-Post Lift Lifting Point - Frame Contact Lift, Single-Post Lift, Two-Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms, front I-braces or rear control arms. Severe damage to the vehicle could result. - Do not position the lift pads under the No. 3 crossmember. NOTE: Adapters maybe necessary to clear vehicle components to lift the vehicle safely. The adapters must be placed at the four designated contact points. Position the adapters so they are centered on the adapter contact area. Lift the vehicle at the applicable lift points. Page 9279 Headlamp Dimmer Switch: Diagrams Page 8075 Symbols Part 3 Page 6651 View 151-9 Page 1980 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Page 8069 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 5865 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Adjustments Front Door Window Glass: Adjustments DOOR WINDOW GLASS ADJUSTMENT 1. Remove the front door trim panel and watershield. 2. Partially lower the front door window glass to within three inches of the full up position. 3. Loosen the nut and washer assemblies. 4. Open the front door. 5. Gently pull the front door window glass fully rearward into the door top glass run. 6. Tighten the nut. 7. NOTE: If the hole is a vertical slotted hole, make sure that the nut and washer assembly is positioned at the bottom of the slot before downward pressure is applied to the window regulator equalizer arm bracket. Apply downward pressure on the window regulator equalizer arm bracket. Page 3300 1. If the valve tappets are to be reused, they must be installed in their original location. Mark the valve tappets for location before removing. Items 8-11: Valve Spring Removal Note 1. CAUTION: The piston must be at the top of its stroke with both the intake and exhaust valves closed prior to removing the valve spring. CAUTION: If a valve drops into the cylinder, remove the cylinder head. Hold the valve in the cylinder head. Remove the spark plug. - Apply a minimum of 689 kPa (100 psi) of compressed air into the cylinder. 2. Using the special tool, compress the valve springs. 3. Remove the following: 1. Valve spring retainer key 2. Valve spring retainer 3. Valve spring 4. Valve stem seal Item 8: Valve Spring Retainer Key Installation Note 1. CAUTION: Do not release the compressed air from the cylinder until after the valve spring keys are installed. After installing the valve spring keys, release the air pressure from the cylinder. Install the spark plug. Items 3-1: Rocker Arm Installation Note Page 8656 Part 1 Page 9413 Page 437 P0350 - P0354: Testing and Inspection P0351 For diagnosis of code P0351 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8125 Test X3-X6 Normal Operation The trailer tow relays are supplied power from the BEC. Ground for the trailer tow parking lamp relay is provided through circuit 576 (DG). Ground for the trailer tow LH turn lamp relay is provided through circuit 374 (DB/WH). Ground for the trailer tow RH turn lamp relay is provided through circuit 378 (BN/YE). Ground control for the trailer tow relay coils is controlled by the SJB. When the trailer tow parking lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 962 (BN/WH). When the trailer tow LH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 52 (YE). When the trailer tow RH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 64 (DG). Possible Causes - circuit 52 (YE) short to power - circuit 64 (DG) short to power - circuit 374 (DB/WH) short to ground - circuit 378 (BN/YE) short to ground - circuit 576 (DG) short to ground - circuit 962 (BN/WH) short to power - trailer tow relay - BEC - SJB Page 5858 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 7126 Refrigerant: Service Precautions CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Page 1283 P1705 - P1709: Testing and Inspection 4R100 For diagnosis of code P1705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5686 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 9063 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Page 3813 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 7427 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. - Make sure the radiator support and front impact severity sensor mating surfaces are clean and debris free. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure First Row SIDE IMPACT SENSOR - FIRST ROW Page 4160 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 1853 Page 8760 Brake Booster Sensor Page 1396 P2005 - P2009: Testing and Inspection P2006 For diagnosis of code P2006 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5000 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 6484 Page 8158 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 Page 917 P1120 - P1124: Testing and Inspection P1121 For diagnosis of code P1121 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9752 Windshield Washer Reservoir: Vehicle Damage Warnings CAUTION: Do not make any electrical connections prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Page 205 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3515 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................................... 11 ft. lb. (15 Nm) Page 227 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0183 refer to chart Locations View 151-10 Page 566 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1981 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Page 7163 Output Shaft Speed (OSS) Sensor Page 6673 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Brake Pedal Position Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position Switch BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 9406 Special Tool(s) Technician Safety Information Heater Hose: Technician Safety Information WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 1273 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7330 Page 5776 ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or 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 approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES [NEW] PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : 04S24 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Page 4598 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER AND PURGE VALVE REMOVAL WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. 1. If removing the canister purge valve, remove the cowl panel. 2. If removing the evaporative emission canister, with the vehicle in NEUTRAL, position it on a hoist. 3. Disconnect the battery ground cable. Page 8730 Page 7491 Part 1 Page 1465 P2130 - P2134: Testing and Inspection P2132 For diagnosis of code P2132 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Brake Pedal Position Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position Switch BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Valve Cover RH Valve Cover: Service and Repair Valve Cover RH CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the upper intake manifold. 2. Remove the ignition coil. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Item 5: RH Valve Cover Gasket Removal Note 1. Do not discard the gasket. It may be reused if it is not damaged. Testing and Inspection Mini ISO Relay: Testing and Inspection Service and Repair Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Electrical Bussed electrical center (BEC) fuse(s): 46 (20A) (trailer tow stop/turn) - 52 (20A) (trailer tow parking) - 58 (30A) - 62 (30A) - 65 (30A) - BEC - Circuity - Relay(s) - Bulb(s) 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. 5. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 6. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 7. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - SCP, ISO or UBP circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for SJB, refer to Information Bus (Module Communications Network). - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the SJB. 8. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 9. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Diagrams Page 4061 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Initial Inspection and Diagnostic Overview Clock: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, verify that the symptom exists and GO to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Page 4609 Evaporative Check Valve: Vehicle Damage Warnings CAUTION: - When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. - Make sure the fuel tube clicks into place when installing the tube. To make sure the tube is fully seated, pull on the tube. Page 1639 Page 4739 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 1156 Inspection Page 8895 Cruise Control Switch: Service and Repair Without Remote Audio Controls SPEED CONTROL SWITCH - WITHOUT REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 1973 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Page 3362 Part 1 Of 4 Page 196 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0171 refer to chart Page 1786 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Service and Repair Front Door Window Regulator: Service and Repair DOOR WINDOW GLASS - FRONT Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. Page 271 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0204 refer to chart Service Precautions Accumulator HVAC: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Page 1357 P1760 - P1764: Testing and Inspection P1761 For diagnosis of code P1761 refer to chart Part 5 Of 9 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0270 P0270 - P0274: Testing and Inspection P0270 For diagnosis of code P0270 refer to chart B1219-B1317 / P0182-P1272 Page 6093 Page 6357 Page 113 P0120 - P0124: Testing and Inspection P0123 For diagnosis of code P0123 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0730 P0730 - P0734: Testing and Inspection P0730 For diagnosis of code P0730 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Locations View 151-13 Page 8024 Locations View 151-16 Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Page 9507 Symbols Part 2 Page 9418 High Beam Relay: Testing and Inspection Page 175 P0150 - P0154: Testing and Inspection P0154 For diagnosis of code P0154 refer to chart P0107-P0193 Page 5459 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Steering Column Opening Cover Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Locations View 151-18 Page 8699 Page 945 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Driver Memory Seat Horizontal Sensor Page 8083 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 Description and Operation Fuel Shut-off Solenoid: Description and Operation LOW PRESSURE SOLENOID SHUT-OFF VALVE Low pressure solenoid shut-off valve which isolates the fuel rail from the upstream fuel system when the engine is OFF. This minimizes the amount of fuel available to flow through the fuel injectors when the engine is off or leak from a damaged fuel rail during and after a crash. The valve is controlled by the PCM fuel shut-off valve circuit and contains an inertia switch. The valve is only on for one second after a key-on or whenever CKP signals are being received by the PCM. Page 5777 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 [NEW] This supplement to 04S24 involves replacing both front wheel hubs and both front wheel rotors as separate components. The hub and rotor assembly kits that were offered when the Safety Recall was launched are no longer available. SERVICE PROCEDURE [NEW] 1.Replace both front wheel hubs and rotors. Refer to Section 204-00 of the 2004 Freestar/Monterey Workshop Manual found on the PTS website for the latest service procedures. Review the following notes during service: ^ Use new bolts, PN W705696-5436, when installing the new hubs. Tighten to 115 Nm (85 lb-ft). ^ When installing the rotor onto the hub, apply a light coating of High Temperature Nickel Anti-Seize Compound, XL-2, to the mating surfaces of the hub and rotor. DO NOT ALLOW ANY ANTI-SEIZE COMPOUND TO GET ONTO THE STUD BOLT THREADS. Make sure that the compound is free of any debris (dirt, rust, etc.) that could cause an excessive rotor run-out condition. ^ Be sure to reinstall any rotor-to-hub screws that were present during disassembly. Tighten screws to 28 Nm (21 lb-ft). ^ Apply a small patch of Threadlock 262, TA-26, to the last five (5) axle shaft joint threads before installing a new axle shaft nut. Tighten the nut to 130 Nm (96 lb-ft). Page 7254 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Drivetrain - Outer CV Joint(s) Broken Constant Velocity Joint: All Technical Service Bulletins Drivetrain - Outer CV Joint(s) Broken TSB 05-9-8 05/16/05 OUTER CV JOINT BROKEN - VEHICLES BUILT BEFORE 5/1/2005 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles built before 5/1/2005, may exhibit a broken outer C/V joint. This may occur when the vehicle steering is turned hard in one direction and the vehicle is accelerated at a high rate. ACTION Replace the outer C/V joint and install restrictors between the inner tie-rod ends and the steering rack. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Replace the halfshaft (right and/or left). Refer to Section 205-04 of the Workshop Manual. 2. Remove the steering gear. Refer to Section 211-00 of the Workshop Manual. If present, note the orientation of the steering gear vent tube. During reinstallation the bellows and vent tube must be installed in the correct orientation. NOTE THE BELLOWS AND CLAMPS ON THE STEERING GEAR ARE DESIGNED TO PROVIDE AN AIRTIGHT SEAL TO PROTECT THE INTERNAL COMPONENTS. IF THE BELLOWS SEAL IS NOT AIRTIGHT THE VACUUM GENERATED DURING TURNING WILL DRAW WATER AND CONTAMINATION INTO THE GEAR CAUSING PREMATURE WEAR. ZIP TIES DO NOT PRODUCE AN AIRTIGHT SEAL AND MUST NOT BE USED IN PLACE OF THE BELLOWS CLAMPS. 3. Drain any excess power steering fluid from the steering gear and clean the exterior of the gear using a suitable solvent. 4. Remove and discard the two (2) inner bellows clamps. New clamps must be installed. 5. Slide the two (2) steering gear bellows aside to allow access to the inner tie-rods. 6. Thoroughly clean any abrasive material from the inside of the bellows area. Thoroughly clean and inspect all the parts being reused. 7. Install the restrictors on each side of the rack between the inner tie-rod and the steering gear housing (Figure 1). 8. Position two (2) new inner bellows clamps onto the steering gear. DO NOT secure the inner bellows clamps at this point. 9. Install the two (2) steering gear bellows over the steering gear. Initial Inspection Differential Assembly: Testing and Inspection Initial Inspection Driveline System Inspection and Verification Halfshafts NOTE: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions. Indentations must be removed. Inspect the boots for evidence of cracks, tears, or splits. Inspect the underbody for any indication of grease splatter near the boots outboard and inboard locations. This is an indication of boot/clamp damage. Page 743 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Axle Bearing: Service and Repair Front Axle Halfshafts, Bearings and Seals Special Tool(s) Material 1. With the vehicle in NEUTRAL, position on a hoist. 2. Remove the front wheel and tire assembly. 3. CAUTION: Remove or tape the brake pads to prevent them from falling out of the anchor plate. CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose. NOTE: Remove the front brake anti-lock sensor harness from the clip. Remove the bolts and position the disc brake caliper aside. Customer Safety Information Impact Sensor: Customer Safety Information WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Page 2798 Ignition Cable: Service and Repair Customers have reported success using the following spark plug wire placement on the coil pack." IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 8824 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 9014 Page 8941 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 1641 View 151-11 System Diagnosis P1335 - P1339: Testing and Inspection For diagnosis of code P1336 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8591 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) REMOVAL 1. CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery. 2. Remove the driver seat. 3. Remove the parts in the order indicated in the illustration and table. Page 8695 View 151-16 Parking Aid Speaker, Front Page 6488 Page 6578 Special Tools Page 2327 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 7568 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 6908 Auxiliary Relay Box Front Blower Motor Resistor Assembly Page 3479 Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Page 9199 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Connector Views Engine Control Module: Connector Views Page 132 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0132 refer to chart Page 643 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 8459 Part 2 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Windshield Side Garnish Moulding Removal Note 1. Pull out at the top and then up to release the lower tabs. Item 3: A-pillar Trim Panel Removal Note 1. Position the door weather strip aside. Item 5: Lower B-pillar Trim Panel Removal Note 1. If equipped with power sliding doors, disconnect the power sliding door switch electrical connector. Item 6: Upper B-pillar Trim Panel Removal Note 1. Remove the upper safety belt anchor nut. Item 12: Quarter Trim Panel Removal Note 1. If equipped with rear auxiliary power, disconnect the electrical connector. Item 15: D-pillar Trim Panel Removal Note 1. Remove the upper safety belt anchor nut. Item 16: C-pillar Trim Panel Removal Note 1. Remove the upper safety belt anchor nut. INSTALLATION 1. To install, reverse the removal procedure. Electrical - ABS/TCS/Park Brake Lamps Flickering Parking Brake Warning Lamp: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 925 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations Page 5908 Part 2 Of 2 3. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed stems: 4. To install, reverse the removal procedure. 5. Bleed the brake system. For additional information, refer to Brake System Bleeding. 6. Inspect the brake system for proper operation. Item 3: Brake Tube Fittings Removal Note 1. Cap the brake line and plug the master cylinder ports. Item 5: Brake Master Cylinder Removal Note 1. Use a suitable suction device to drain the reservoir before removal. 2. If removing the brake booster, position the brake master cylinder forward. Item 14: Brake Booster Removal Note Page 2760 6. Prepare the shock tower and alignment plate surfaces. ^ Remove any burrs. ^ Clean and paint any exposed metal. 7. Position the alignment plate. Loosely install the nuts. 8. Adjust the camber and caster. 9. Tighten the nuts. 10. Check the alignment settings. Follow the manufacturer's instructions. Readjust the camber and caster as necessary. Page 7006 Illustration 2 Of 2 3. Remove the parts in the order indicated in the illustrations and tables. Item 9: Lower Radiator Support Bolt Removal Note 1. Detach the line routing clips. 2. Correctly support the lower radiator support before removing the lower radiator support bolts. Item 10: Lower Radiator Support Removal Note 1. Correctly support the cooling module before removing the lower radiator support. INSTALLATION 1. To install, reverse the removal procedure. Page 9386 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Component Locations Page 4337 Electronic Throttle Monitor Operation, Part 1 Electronic Throttle Monitor Operation, Part 2 Accelerator and Throttle Position Sensor Inputs Accelerator Pedal Position Sensor Check Accelerator Pedal Position Sensor Check: Throttle Position Sensor Check Throttle Position Sensor Check: Throttle Plate Position Controller (TPPC) Outputs Page 3489 Item 6: Spark Plug Wire-to-Spark Plug Removal Note 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 1442 P2105 - P2109: Testing and Inspection P2107 For diagnosis of code P2107 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2427 Page 7237 Solar Sensor: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Solar Radiation Sensor The solar radiation sensor supplies information to the EATC module indicating sunload. Traction Control - Short Duration Activation Steering Angle Sensor: All Technical Service Bulletins Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Page 718 P0740 - P0744: Testing and Inspection P0741 Torqshift For diagnosis of code P0741 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 2019 View 151-20 Page 865 P0980 - P0984: Testing and Inspection P0982 For diagnosis of code P0982 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 7842 Page 2248 View 151-22 Technician Safety Information Clockspring Assembly / Spiral Cable: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the steering wheel removal and installation procedure. - Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury. Page 3211 CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Frame Contact Lift, Single-Post Lift, Two-Post Lift Lifting Point - Frame Contact Lift, Single-Post Lift, Two-Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms, front I-braces or rear control arms. Severe damage to the vehicle could result. - Do not position the lift pads under the No. 3 crossmember. NOTE: Adapters maybe necessary to clear vehicle components to lift the vehicle safely. The adapters must be placed at the four designated contact points. Position the adapters so they are centered on the adapter contact area. Lift the vehicle at the applicable lift points. Page 4741 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 111 P0120 - P0124: Testing and Inspection P0122 For diagnosis of code P0122 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 604 P0603-P2198 / U0309-U2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 5421 Flex Plate: Service and Repair Flexplate or Flywheel and Crankshaft Rear Seal Special Tools And Equipment Special Tools And Equipment Special Tool(s) Page 8578 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Driver Side Page 8932 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 P0400 P0400 - P0404: Testing and Inspection P0400 For diagnosis of code P0400 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7576 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 6558 Page 7985 Erasing Channels 1. NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for programming. To erase all three programmed channels, hold down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. Page 1128 P1405 - P1409: Testing and Inspection P1406 For diagnosis of code P1406 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7829 striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the driver seat. 5. NOTE: - The manual seat track seat position sensor is shown, the power seat track position sensor is similar. - Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8072 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 3786 Page 9065 Special Tool(s) Page 5478 View 151-6 Page 2429 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. Item 2: HO2S and Catalyst Monitor Sensors Removal Note Liftgate Ajar Switch Page 4852 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL VALVE The idle air control (IAC) valve assembly controls 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. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: - No touch start - Cold engine test idle for rapid warm-up - Idle (corrects for engine load) - Stumble or stalling on deceleration (provides a dashpot function) - Over-temperature idle boost. Page 6492 Page 281 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The malfunction indicator lamp (MIL) (Figure 17) alerts the driver that the powertrain control module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Charts - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Page 1017 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1262 refer to chart Page 5705 Brake Pedal Assy: Exploded Views Part 1 Of 3 Part 2 Of 3 Page 8435 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 636 P0700 - P0704: Testing and Inspection P0704 For diagnosis of code P0704 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7772 Impact Sensor: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Page 8708 Door Position Switch: Locations Sliding Door Contact Switch, Left View 151-15 Page 6534 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 8476 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Page 1054 P1270 - P1274: Testing and Inspection P1274 OBD II - Base Gasoline For diagnosis of code P1274 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4309 View 151-5 Page 1480 P0603-P2198 / U0309-U2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-5 Page 3271 Assemble the special tools, then place the crankshaft front seal onto the special tools. 3. Using the special tools, install the crankshaft front seal. Item 6: Crankshaft Pulley Installation Note 1. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley. Using the special tool, install the crankshaft pulley. Item 3: Subframe Bolt Installation Note 1. Raise the subframe into position, then install the bolts. 2. Connect the RH front anti-lock brake wheel sensor electrical connector. Page 375 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8390 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. General Procedures Heater Hose: Service and Repair General Procedures HEATER HOSE COUPLING Special Tool(s) SPECIAL TOOL(S) DISCONNECT CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. 1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Depressurize the engine cooling system. 2. Push the heater hose toward the tube to fully expose the locking tabs. 3. NOTE: - When compressing the white coupling retainer with the special tool, the special tool must be perpendicular to and on the highest point of the coupling. - If the heater hose coupling is accessible, the retainer tabs can be compressed by hand to disconnect the heater hose. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. Page 1349 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9324 License Plate Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: All Technical Service Bulletins Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 7811 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 5578 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Application and ID Hazard Warning Flasher: Application and ID The Flasher function for this vehicle is provided by the Smart Junction Box (SJB). Page 2617 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Item 17: Seat Cushion Foam Pad Removal Note Page 3524 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two 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 percent of the highest reading. Page 9198 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. Gap Spark Plug: Specifications Gap Spark Plug Gap.................................................................................................................................... ...................................... 1.3-1.4 mm (0.052-0.056 in) Page 8082 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Customer Safety Information Impact Sensor: Customer Safety Information WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Page 1016 P1260 - P1264: Testing and Inspection P1262 OBD II - Base Gasoline For diagnosis of code P1262 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2625 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Page 5064 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 5341 Item 3: Lower Control Arm Ball Joint Pinch Bolt Removal Note 1. Remove and discard the nut and bolt. Item 5: Halfshaft Assembly Removal Note 1. Separate the rear axle halfshaft assembly from the hub. Using the special tools, press the outboard CV joint until it is loose in the hub. Remove the special tool. Separate the outboard CV joint from the hub. 2. CAUTION: Do not damage the transmission differential seal. Remove the halfshaft with both hands. Item 5: Halfshaft Assembly Installation Note 1. CAUTION: Install a new circlip every time the halfshaft is removed from the transmission differential. On the RH halfshaft only, Install a new axle circlip in the groove in the inboard CV joint stub shaft. ^ Start one end in the groove and work the circlip over the shaft and into the groove to prevent the clip from overexpanding. 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: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. NOTE: - Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the RCM has the DTC B1231 (Crash Data Memory Full) in memory, the repair of the vehicle's supplemental restraint system (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. 2. 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. 3. When the driver air bag module has deployed a new clockspring must be installed. 4. Inspect the entire vehicle for damage, including the following components: - steering column. - instrument panel knee bolsters and mounting points. - instrument panel braces and brackets. - instrument panel and mounting points. - seats and seat mounting points. - safety belts, safety belt buckles, and safety belt retractors. - supplemental restraint system (SRS) wiring, wiring harnesses, and connectors. 5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Page 8167 Trailer Connector: 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. 95-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 439 P0350 - P0354: Testing and Inspection P0352 For diagnosis of code P0352 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Locations View 151-13 Page 1140 Inspection Page 7827 Seat Sensor/Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Page 6878 Page 6776 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 3: Stabilizer Bar Links Inspection Note 1. Inspect the stabilizer bar link ball Joints and boots for wear. If necessary, install new parts. Item 4: Subframe Bolt Removal Note 1. Remove and discard the subframe bolts. 2. Lower the rear of the subframe 5 to 8 cm (2 to 3 inch) to gain access to the stabilizer bar bracket retaining bolts. Item 8: Stabilizer Bar Bushing Inspection Note 1. Inspect the stabilizer bar bushings for wear. If necessary, install new parts. Item 4: Subframe Bolt Installation Note 1. CAUTION: Do not use power tools to install the subframe bolts. Install new subframe bolts using hand tools. Page 6343 P0605 P0605 - P0609: Testing and Inspection P0605 OBD II - Base Gasoline For diagnosis of code P0605 refer to Note 12: NOTE 12: Be sure to check for aftermarket performance products before replacing the PCM. If replacement is necessary refer to Flash Electrically Eraseable Programmable Read Only Memory. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0605 refer to chart Seat Adjust Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Adjust Switch, Driver Side Front Page 3440 4. Using the special tool, remove the crankshaft pulley. 5. Raise the subframe into position, then install the bolts. Item 9: Crankshaft Front Seal Removal Note 1. Using the special tool, remove the front crankshaft front seal. Item 11: Engine Front Cover Stud Bolt Removal Note 1. Disconnect the catalyst monitor sensor electrical connector. Page 1822 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Page 854 P0975 - P0979: Testing and Inspection P0978 For diagnosis of code P0978 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service Precautions Compass: Service Precautions CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. Page 319 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9517 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 1284 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1066 P1275 - P1279: Testing and Inspection P1277 OBD II - Base Gasoline For diagnosis of code P1277 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s), Part 1 Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Page 8529 Page 7095 Heater Hose: Vehicle Damage Warnings CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. Page 3644 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 4 Page 4060 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 1121 P1400 - P1404: Testing and Inspection P1401 For diagnosis of code P1401 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4050 Item 6: Spark Plug Wire-to-Spark Plug Removal Note 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 649 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0708 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle Page 9440 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Locations View 151-10 Page 5038 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 9633 Page 4308 View 151-4 Page 1587 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 6311 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Service and Repair Air Cleaner Housing: Service and Repair AIR CLEANER ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Air Cleaner Cover Removal Note 1. NOTE: No tools are needed to remove the air cleaner cover. Removal should be carried out using hands only. Release the clamps and separate the air cleaner cover from the air cleaner tray. INSTALLATION 1. To install, reverse the removal procedure. Page 3757 View 151-4 Locations View 151-13 Page 1757 Note: The bussed electrical center is located in the engine compartment. Page 7594 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Page 7013 Control Assembly: Service and Repair CLIMATE CONTROL ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Center Instrument Panel Finish Panel Removal Note 1. Remove the center instrument panel finish panel. INSTALLATION 1. To install, reverse the removal procedure. Page 9193 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 7044 Illustration 3 Of 3 6. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps. INSTALLATION 1. To install, reverse the removal procedure. - Install new O-ring seals lubricated in clean mineral oil. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Fill the engine cooling system. 3. Evacuate, leak test and charge the refrigerant system. Page 4462 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 3798 Page 5320 11. Remove the oil filler cap. 12. Install the special tool. (front of engine compartment) 13. Install the special tool. (rear of engine compartment) Page 7614 Item 2: Seat Side Trim Panel And Recliner Handle Removal Note 1. Using a suitable tool, carefully pry the side shield for access to the recliner handle clip and remove the clip and handle. - Remove the two screws and trim panel. Item 3: Seat Side Trim Panel Removal Note 1. Remove the two screws and trim panel. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Tether Anchor/Safety Belt Anchor Buckle Bolt Installation Note 1. Make sure the anti-rotation tab is correctly aligned before tightening the fastener. Item 3: Seat Side Trim Panel Installation Note 1. Install the trim panel and two screws. Item 2: Seat Side Trim Panel And Recliner Handle Installation Note 1. Install the trim panel and two screws. - Install the recliner handle and clip. Page 6271 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Page 4377 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 1752 Page 3188 10. Using special tool 205-343 (T95T-3514-A), secure the 2 inner bellows clamps. 11. Reinstall the steering gear per Section 211-00 of the Workshop Manual. 12. Perform a front wheel alignment. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050908A 2004-2005 2.5 Hrs. Freestar/Monterey Replace One Halfshaft, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) 050908B 2004-2005 2.8 Hrs. Freestar/Monterey Replace Both Halfshafts, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) DEALER CODING CONDITION BASIC PART NO. CODE 3B436 01 Disclaimer Page 7889 Page 6682 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 8119 PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE Test W1 Test W1-W4 Page 1099 P1380 - P1384: Testing and Inspection P1381 For diagnosis of code P1381 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2611 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor (OCS) system is found only on the front passenger seat. The front passenger seat OCS system is comprised of a silicone gel-filled bladder mounted in the seat cushion, a pressure sensor that is mounted to the seat frame and an electronic control unit which is also mounted to the seat frame. Pressure is applied to the OCS system bladder when weight of any occupant or object in the front passenger seat is present. The pressure is then transferred through a tube, is sensed by the OCS system pressure sensor, then electronically communicated to the OCS system electronic control unit (ECU). Based on preprogrammed set points the OCS system ECU will inform the restraints control module (RCM), via a high-speed controller area network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module and passenger safety belt pretensioner are to be deployed in the event of a deployable collision. The RCM may also use this information to illuminate/not illuminate the passenger air bag deactivation (PAD) indicator. When an OCS system fault is present, the air bag indicator lamp will illuminate or the air bag warning chime will be activated (if an air bag indicator fault is present). The SRS then defaults the passenger air bag module to ON (activated) regardless of the size of the occupant in the front outboard passenger seat. The OCS system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. OCS system components are not to be installed separately. If installing a new OCS system, OCS system component or seat cushion foam pad, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. The OCS system also interprets a variable voltage signal provided by the safety belt tension sensor to identify the presence of a child safety seat in the front outboard passenger seat. The OCS system then communicates with the restraints control module (RCM), automatically deactivating the passenger air bag module and passenger safety belt pretensioner. Refer to Safety Belt Tension Sensor. Page 9155 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 1909 Air Bag Control Module: Diagrams Page 3660 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. 5. Fill and bleed the cooling system. Item 6: Thermostat Removal Note 1. Mark the location of the vent pin before removing the thermostat. Item 3: Thermostat Housing-to-Engine Bolts Installation Note 1. Tighten the thermostat housing-to-engine bolts in two stages. ^ Stage 1: Tighten to 8 Nm (71 inch lbs.). ^ Stage 2: Tighten an additional 60 degrees. Page 8319 Page 7581 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 1811 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Locations View 151-15 Page 7801 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustration(s) and table(s). Item 1: Recliner Handle Cover Removal Note Page 2292 Hazard Warning Switch: Diagrams Page 3854 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 1100 Inspection Page 7296 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 7814 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Locations Brake Booster Sensor Page 9447 Ambient Light Sensor: Service and Repair LIGHT SENSOR REMOVAL 1. Remove the LH and RH windshield side garnish mouldings. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Description and Operation Console: Description and Operation CONSOLE The front floor console provides extra storage space. If equipped, the overhead console incorporates two interior lights with switches and the vehicle message center. Page 6006 View 151-29 Page 4245 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Upper Intake Manifold Intake Manifold: Service and Repair Upper Intake Manifold Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Disconnect the battery ground cable. 3. Partially drain the cooling system. 4. Remove the wiper motor and pivot assembly. 5. Remove the engine air cleaner outlet tube. Page 2329 Disclaimer Page 4538 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 7334 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 7081 1. Install a long bolt or threaded rod with the same diameter and thread pitch, in place of the LH instrument panel bolt, to support the instrument panel while allowing it to be moved away from the dash panel. Item 9: Instrument Panel Bolt Removal Note 1. Install a long bolt or threaded rod with the same diameter and thread pitch, in place of the LH instrument panel bolt, to support the instrument panel while allowing it to be moved away from the dash panel. Item 12: Instrument Panel Support Brace Bolt Removal Note 1. Remove the bolts and the center instrument panel support brace. Item 14: Instrument Panel Bolt Removal Note 1. Loosen the RH instrument panel bolts one half of the bolt length, but do not completely remove the bolts. Item 15: Instrument Panel Removal Note 1. Working through the glove compartment opening, remove the bolt. 2. Position the left side of the instrument panel 3 inches away from the dash panel. Item 22: Wire Harness Removal Note 1. Detach the wire harness from the heater core cover. INSTALLATION 1. To install, reverse the removal procedure. 2. Fill the engine cooling system. Page 6463 Auxiliary Relay Box Page 4805 Page 3587 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Service and Repair License Plate Bracket: Service and Repair LICENSE PLATE HOUSING REMOVAL 1. Remove the liftgate trim panel. 2. Remove the parts in the order indicated in the illustration and table. Item 4: License Plate Housing Removal Note 1. Disconnect the liftgate handle actuating cable and position aside. INSTALLATION 1. To install, reverse the removal procedure. Page 7861 Alarm Horn: Service and Repair ANTI-THEFT ALARM HORN REMOVAL 1. Disconnect the battery. 2. Remove the right rear interior trim panel. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8314 Apply a bead of urethane adhesive to the sliding door glass on the primed area. 8. CAUTION: Open the windows to prevent the sliding door glass from being pushed out by the air pressure if the door is closed. Install the sliding door window glass. 9. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. Specifications Brake Hose/Line: Specifications Brake line bracket bolts (front) ............................................................................................................. .................................................... 17 Nm (13 ft. lbs.) Brake line bracket bolts (rear) ........................... ....................................................................................................................................... 22 Nm (16 ft. lbs.) Brake line fittings ......................................................................................................................... ............................................................ 17 Nm (13 ft. lbs.) Page 4348 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 8795 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling Pinpoint Test. NOTE: Refer to Multimeter User's Manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, install a new switch; otherwise, return to the calling Pinpoint Test. Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Page 6877 Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The fuel tank pressure (FTP) sensor (Figure 103) or inline fuel tank pressure (FTP) sensor (Figure 104) is used to measure the fuel tank pressure during the EVAP Leak Check Monitor. Page 7452 Part 1 Page 2618 1. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit or installing a new seat cushion trim cover, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 22: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 24: Occupant Classification Sensor (OCS) Removal Note 1. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. Locations View 151-6 Page 5034 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 6485 Body - Roof Rack Side Rail Cover Installation Procedure Roof Rack Frame: Technical Service Bulletins Body - Roof Rack Side Rail Cover Installation Procedure Article No. 03-20-13 10/13/03 BODY - ROOF RACK SIDE RAIL COVER - INSTALLATION INSTRUCTIONS FORD: 2004 FREESTAR MERCURY: 2004 MONTEREY ISSUE 2004 Freestar/Monterey Roof Rack Side Rail Covers are not installed at the assembly plant. The covers are shipped in a box inside the vehicle, and need to be installed before delivering the vehicle to the customer. ACTION Install the roof rack side rail covers per the Service Procedure below, and per (Figure 1) of this TSB. NOTE TIME FOR INSTALLING THE ROOF RACK SIDE RAIL COVERS IS ALREADY INCLUDED IN REIMBURSED LABOR TIME FOR PDI. SERVICE PROCEDURE NOTE BE SURE TO ALIGN THE BOSSES ON BACK/INSIDE OF THE COVERS WITH THE MATING RETAINING HOLES IN THE ROOF RACK SIDE RAIL SUPPORTS. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE BOSSES. 1. Select the cover for the correct side and align the cover to the mating support. The covers are marked on the back with RH or LH for Right Hand and Left Hand sides. 2. Snap the cover in place horizontally until cover is flush to side rail. Diagrams Blower Motor Resistor Blower Motor Resistor Page 8761 Power Mirror Switch: Testing and Inspection Page 8288 Page 1373 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6186 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 7950 Parking Assist Warning Indicator: Service and Repair Rear Parking Aid Speaker PARKING AID SPEAKER - REAR REMOVAL 1. Remove the RH D-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. With Remote Audio Controls Cruise Control Switch: Service and Repair With Remote Audio Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7457 Part 3 Part 4 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS Page 2029 Page 310 Inspection Page 7169 Page 7418 Diagrams Page 7175 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 1 Page 699 P0730 - P0734: Testing and Inspection P0731 4R70W For diagnosis of code P0731 refer to chart Part 3 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8196 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 4691 View 151-11 Page 1157 P1460 - P1464: Testing and Inspection P1463 For diagnosis of code P1463 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6868 View 151-27 Page 9192 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 4R70W P1705 - P1709: Testing and Inspection 4R70W For diagnosis of code P1705 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Connector Views Fuse Block: Connector Views Bussed Electrical Center (BEC) Page 3427 1. Install the timing chain tensioner and bolts. 2. If necessary, retract the tensioner pad retracting mechanism and insert a retaining pin. 3. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position. 4. Turn the camshaft gear so that the timing mark is on the bottom of the balance shaft. Page 4721 Accelerator Pedal: Service and Repair ACCELERATOR PEDAL AND SHAFT REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Accelerator Cable Removal Note Page 1204 P1515 - P1519: Testing and Inspection P1517 For diagnosis of code P1517 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1460 P2125 - P2129: Testing and Inspection P2128 For diagnosis of code P2128 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 7543 View 151-14 Page 4274 Fuel Pressure Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5677 Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 5310 Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 8147 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 6119 Page 1230 P1565 - P1569: Testing and Inspection P1566 For diagnosis of P1566 refer to chart DTC Index P0500 - P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection> Page 3871 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Page 6277 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Page 4814 Fuel Rail: Service and Repair FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR Disconnect Tool, Spring Lock Coupling (3/8 Inch) SPECIAL TOOL(S) REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel pressure. 3. Remove the fuel charging wiring harness. Page 2365 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Technician Safety Information Seat Occupant Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes at the beginning of the removal procedure. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - Do not separate components. Page 8141 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Page 6690 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Page 7207 Blower Motor Switch: Description and Operation Electronic Automatic Temperature Control BLOWER MOTOR SPEED CONTROL The blower speed control: - is located on the heater core and evaporator core housing near the blower motor. - PWM signals from the EATC module to control a high-current, variable ground feed for the blower motor. - varies the blower motor speed and is controlled by the EATC module software. - has a delay function to provide a gradual increase or decrease in blower motor speed under all conditions. Page 8312 2. NOTE: Lubricate the existing adhesive with water to aid the special tool while cutting. Using the special tool, cut the adhesive from the sliding door window glass. 3. NOTE: - There are 4 locator pins on the sliding door window glass that hold the glass in place during assembly. - An assistant may be required to avoid damaging the door when the door glass comes loose. Using the special tool, distance the sliding door glass from the sliding door and discard the glass. 4. Remove the locator pins from the door skin and discard the pins. 1 Rock the pins back and forth applying pressure to remove the pins. 2 Rotate the pins 90 degrees left or right and remove the pin. 3 Using a suitable tool, cut the head off the pin and retrieve it from the bottom of the door. 5. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Sliding Door Window Glass Installation Note CAUTION: - A new sliding door window glass must be installed to prevent wind noise or water leaks. - After installing the new sliding door window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. Locations View 151-6 Page 900 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2049 Page 2728 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7193 Control Module HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL EATC Module The EATC module: is located in the instrument panel. - has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs). - utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble codes (DTCs). These DTCs direct the technician to the inoperative component. - display will switch between Celsius and Fahrenheit when the instrument cluster display is toggled. Main Light Switch View 151-8 Locations Page 9767 View 151-22 Page 5173 Service Procedure, Includes Time To Check And Fill Transmission Fluid (Do Not Use With 1 7526A, 17566A, 17508A, 17603A, 9600A, 9601A) 061813B 2004-2007 1.3 Hrs. Freestar/Monterey, 2000-2003 Windstar: Replace Transaxle Vent Following Service Procedure, Includes Time To Remove And Reseal The Cowl Panel Grille, Check And Fill Transmission Fluid (Do Not Use With 17526A, 17566A, 17508A, 17603A, 9600A, 9601A, 061410A) DEALER CODING CONDITION BASIC PART NO. CODE 7L282 41 Disclaimer Page 4458 Page 369 P0275 - P0279: Testing and Inspection P0279 For diagnosis of code P0279 refer to chart B1219-B1317 / P0182-P1272 P1000 P1000 - P1004: Testing and Inspection P1000 For diagnosis of code P1000 refer to chart P0723-P1150 Note 19: DTC P1000 is ignored in the KOEO and KOER self-test. Disregard DTC P1000 and continue as directed. If there is no link in the chart then: - This code is not a valid code for this vehicle Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 7698 Seat Belt Retractor: Description and Operation DUAL LOCKING MODE RETRACTORS WARNING: After any vehicle collision, the safety belt system at all outboard seating positions (except driver, which has no "automatic locking retractor" feature) must be checked by a qualified technician to verify that the "automatic locking retractor" feature for child seats is still functioning properly, in addition to other checks for proper safety belt system function. A belt and retractor assembly must be replaced if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating properly when checked according to the procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make sure it is not in the automatic locking retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The emergency locking retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in ALR mode and the webbing will not pull back out of the retractor. To disengage the ALR mode, let the webbing retract back onto the spool. The ALR mode is disengaged when the webbing is free to move out and back into the retractor. The automatic locking mode must be used when installing a child safety seat in the front or rear passenger seating positions where dual locking mode retractors are provided. ENERGY MANAGEMENT RETRACTOR This vehicle has a safety belt system with an energy management feature at the front seating positions to help further reduce the risk of injury in the event of a head-on collision. The energy management retractor feature is designed to pay out webbing in a controlled manner. This feature is designed to help reduce the belt force acting on an occupant's chest. Page 9342 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 534 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 224 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6281 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Diagram Information and Instructions Accelerator Pedal: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. P0552 P0550 - P0554: Testing and Inspection P0552 For diagnosis of code P0552 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5209 ^ Taurus with floor shifter (Figure 7) 12. Connect the shift cable, if removed. 13. Install the air cleaner cover and outlet pipe. NOTE USE THE ALIGNMENT NOTCHES TO CORRECTLY ALIGN THE AIR CLEANER COVER TO THE AIR CLEANER TRAY. 14. Install the air cleaner housing clamp(s). 15. Connect the air cleaner outlet pipe to the throttle body and tighten to 35 lb-in (4 N.m). 16. Connect the crankcase vent tube to the air cleaner outlet pipe. 17. Connect the MAF sensor electrical connector. 18. Windstar, Freestar, and Monterey only, follow TSB 06-14-10 to seal and install the cowl panel grille. Parts Block OTHER APPLICABLE ARTICLES: 06-14-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061813A 2000-2007 Taurus, 0.5 Hr. 2000-2005 Sable: Replace Transaxle Vent Following P0405 P0405 - P0409: Testing and Inspection P0405 For diagnosis of code P0405 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and P0330 P0330 - P0334: Testing and Inspection P0330 For diagnosis of code P0330 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5288 Item 2: Transmission Fluid Cooler Tubes (at Transaxle) Removal Note 1. Depress the tabs on the plastic insert retainer and remove the cooler line from fitting. Item 3: Transmission Fluid Cooler Tubes (at Radiator) Removal Note 1. Using the special tool, disconnect the fluid cooler tubes from the fittings at the radiator. Item 2: Transmission Fluid Cooler Tubes (at Transaxle) Installation Note 1. Insert the tubes in the transaxle fittings to seat the retaining tabs. Slightly pull back on the tubes to make sure that the tubes are locked. Page 3143 CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on hoist without first checking for possible interference. Check for interference between the upright flanges of the hoist rails and the underbody. If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to provide clearance. Lifting Points-Frame Contact Lift, Single-Post Lift, Two-Post Lift Lifting Point - Frame Contact Lift, Single-Post Lift, Two-Post Lift CAUTION: Under no circumstances should the vehicle be lifted by the front control arms, front I-braces or rear control arms. Severe damage to the vehicle could result. - Do not position the lift pads under the No. 3 crossmember. NOTE: Adapters maybe necessary to clear vehicle components to lift the vehicle safely. The adapters must be placed at the four designated contact points. Position the adapters so they are centered on the adapter contact area. Lift the vehicle at the applicable lift points. Page 8070 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 2656 Page 1336 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3085 Page 5683 View 151-8 Locations View 151-18 Page 1385 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Restraints - Seat Belts Slow to Retract Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Sliding Door Entry Lamp, Left Resistor Cap 1 Throttle Body Housing Throttle Body: Description and Operation Throttle Body Housing THROTTLE BODY HOUSING The throttle body housing assembly is a single piece of aluminum casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Features of the Throttle Body Assembly include: 1. Idle air control (IAC) valve assembly mounted directly to the throttle body assembly (some vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps for PCV, EGR, EVAP and miscellaneous control signals (some vehicles only). 5. PCV air return (if applicable). 6. A throttle body-mounted throttle position (TP) sensor. Typical Attention Decal Locations 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure 110) advising not to clean. Page 6248 Technician Safety Information Windshield Washer Pump: Technician Safety Information WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The air conditioning evaporative temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Page 543 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0975 P0975 - P0979: Testing and Inspection P0975 For diagnosis of code P0975 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8272 Page 3198 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Page 8488 Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING NOTE: All remote transmitters must be programmed at the same time. 1. The vehicle must be electronically unlocked before entering program mode (via remote transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module has successfully entered program mode, it will lock and then unlock all doors. 3. Within 20 seconds, press any button on a remote transmitter, and the doors will lock and then unlock to confirm that each remote transmitter has been programmed. Repeat this step for each remote transmitter. 4. If the door locks do not respond for any remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of remote transmitters are attempted to be programmed. 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last remote transmitter was programmed. - The maximum number of remote transmitters have been programmed. Page 5250 View 151-6 Page 6483 Page 4899 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 1307 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3106 Page 4604 Evaporative Canister Filter: Service and Repair DUST SEPARATOR REMOVAL 1. With the vehicle in NEUTRAL, position on a hoist. 2. WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Electrical - ABS/TCS/Park Brake Lamps Flickering ABS Light: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 5442 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 5245 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. P1650 P1650 - P1654: Testing and Inspection P1650 For diagnosis of code P1650 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2030 ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 6408 Page 8306 1. Using the special tool, install the new rivets. Page 4312 Engine Controls, A/T - Various Driveability Issues/DTC's Firewall: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 3421 CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the generator. 3. Remove the coolant pump. 4. Remove the camshaft synchronizer. 5. Remove the parts in the order indicated in the illustrations and tables. Part 1 Of 3 Part 2 Of 3 Page 1930 Page 340 P0260 - P0264: Testing and Inspection P0264 For diagnosis of code P0264 refer to chart B1219-B1317 / P0182-P1272 Page 6223 Page 43 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2810 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Description and Operation High Pressure Safety Valve HVAC: Description and Operation A/C COMPRESSOR PRESSURE RELIEF VALVE An A/C compressor pressure relief valve is incorporated in the compressor manifold and tube assembly to: - relieve unusually high refrigerant system discharge pressure buildups. - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Page 7437 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Page 9659 View 151-9 Specifications Thermostat: Specifications Thermostat Opening Temperatures Starts to open ............................................................................. ........................................................................................................ 87-91°C (188-195°F) Fully open .............................................................................................................................................................. .......................................... 100°C (212°F Page 4088 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................................... 11 ft. lb. (15 Nm) Page 7521 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Service and Repair Horn Switch: Service and Repair HORN SWITCH REMOVAL 1. Remove the driver air bag module 2. Remove the parts in the order indicated in the illustration and table. Item 3: Horn Switch Spring Removal Note 1. The 4 horn switch springs are not attached. To avoid losing the springs use caution when removing the horn switch. INSTALLATION 1. To install, reverse the removal procedure. Page 2276 Page 1714 Page 1881 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 9331 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. Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. Page 4113 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Brakes - Accelerated rear Brake Pad Wear Brake Rotor/Disc: All Technical Service Bulletins Brakes - Accelerated rear Brake Pad Wear TSB 04-26-10 12/31/04 REAR BRAKE LINING ACCELERATED WEAR FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit accelerated rear brake pad lining wear, heavily scored rear rotors, or metal pickup in the rear lining. ACTION Replace the rear brake pad linings, machine the rotors as required. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042610A 2004-2005 0.7 Hr. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads Only 042610B 2004-2005 1.6 Hrs. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads, Machine Both Rear Brake Rotors On Vehicle DEALER CODING CONDITION BASIC PART NO. CODE 2200 42 Disclaimer Page 8799 Page 5790 ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or 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 approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES [NEW] PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : 04S24 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Recall - Front Hub & Rotor Replacement Technical Service Bulletin # 04S24S1 Date: 060322 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated on September 2, 2004 Diagrams Page 9719 Windshield Washer Switch: Diagrams Page 378 P0280 - P0284: Testing and Inspection P0283 For diagnosis of code P0283 refer to chart B1219-B1317 / P0182-P1272 Page 4880 Page 2620 Part 3 Part 4 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS Page 6213 Relay Box: Diagrams Smart Junction Box (SJB) Page 2191 Page 4048 Ignition Cable: Service and Repair Customers have reported success using the following spark plug wire placement on the coil pack." IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 73 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0107 refer to chart Page 3087 Page 1865 Page 8991 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Page 5139 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Steering Column Opening Cover Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Page 6462 Page 3729 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Recall 03V457000: Power Steering Line Inspection Power Steering Line/Hose: Recalls Recall 03V457000: Power Steering Line Inspection DEFECT: On certain minivans, the power steering low-pressure line may not be fully seated at the rack and pinion steering gear. If this line becomes disconnected, it may create the potential for fluid to come into contact with the exhaust system, which could result in smoke or fire. REMEDY: Dealers will inspect the power steering low-pressure line to ensure that it is seated properly at the rack and pinion steering gear. The manufacturer has reported that owner notification began November 10, 2003. Owners may contact Ford at 1-800-392-3673. Page 7212 Page 1914 Air Bag Control Module: Vehicle Damage Warnings CAUTION: - Installing a J-nut in place of a weld nut is not a recommended repair. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. - Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. Page 9376 Symbols Part 4 Page 9425 Page 8441 Special Tool(s) Page 8664 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 701 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 79 Inspection Page 6603 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 9430 Page 2528 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 283 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0207 refer to chart Page 9334 License Plate Lamp: 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. 92-1 Page 938 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9701 3. Position the door window glass halfway down to gain access to the door window glass rivets. - Remove the rivets. Item 4: Rivet Removal Removal Note 1. Remove the rivets. Item 5: Front Door Window Regulator Removal Note 1. Disconnect the electrical connector. 2. WARNING: Prior to power window motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. Failure to place the regulator arms in a fixed position can cause the spring to suddenly release resulting in personal injury. NOTE: The counterbalance spring assists the window in the upward direction. Remove the bolts and the window regulator motor. Item 4: Rivet Installation Note 1. Using the special tool, install the rivets. Item 1: Rivet Installation Note 1. Using the special tool, install the rivets. Page 6984 Special Tool(s) Page 1777 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 9374 Symbols Part 2 Description and Operation Keyless Entry Transmitter: Description and Operation Remote Keyless Entry (RKE) External Antenna The SJB utilizes an external coaxial antenna to receive remote transmitter signals. Remote Transmitter The remote transmitter will: lock or unlock all vehicle doors and liftgate without a key. - unlock/open a RH power sliding door and/or LH power sliding door (if equipped). - activate the perimeter alarm. - arm and disarm the perimeter anti-theft system (if equipped). The remote transmitter has a minimum operating range of 10 m (33 feet). Remote Transmitter Lock/Unlock Control - Unlock The remote transmitter provides unlock functions independently of key position, vehicle speed, or transmission position. The remote transmitter provides a 2-step process for unlocking the doors. Upon receipt of the first request for unlocking the doors, the remote transmitter requests the SJB to unlock the driver door only and activate perimeter lighting (if equipped). If another unlock request is received within 3 seconds of the first, the remote transmitter requests that both front doors, sliding doors and liftgate be unlocked. Remote Transmitter Lock/Unlock Control - Lock The remote transmitter provides lock functions independently of key position, vehicle speed or transmission position. The remote transmitter requests that all the doors be locked when the remote transmitter LOCK button is pressed. When the LOCK button is pressed once all doors lock. If the LOCK button is pressed again within 3 seconds of the first, the horn will chirp to confirm all doors (and hood, if equipped with alarm) are locked and closed. If any door, liftgate, or hood (with perimeter alarm) is ajar when the second lock request is received, 2 chirps will be heard. Remote Transmitter - Driver/Passenger Power Sliding Door Open/Close The remote transmitter feature provides open and close functionality for power sliding doors when the transmission is in PARK and the speed is less than 5 km/h (3 mph). Pressing the power sliding door button on the remote transmitter twice within 3 seconds opens the door. With the power sliding door open, pressing the power sliding door button twice within 3 seconds closes the door. Panic Alarm The panic alarm feature provides audible and visual alarms which are evident from the exterior of the vehicle. Activation of the panic alarm is accomplished by pressing the PANIC button on a remote transmitter whenever the key is in the OFF position. The SJB requests that the turn signals are flashed and horn sounds until the PANIC button is pressed again, 2 minutes and 45 seconds has elapsed since the time of activation, or the key is cycled to the ON position. Perimeter Lighting The perimeter lighting feature illuminates the exterior of the vehicle while the user approaches and enters the vehicle to provide better visibility to the user. Diagrams Locations View 151-15 Page 4926 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System Inertia Fuel Shutoff (IFS) Switch Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 87) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Reset RESET INSTRUCTIONS 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). 4. Turn key to on or start position for a few seconds, then off again. 5. WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. Again, check for leaking natural gas. Page 4783 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 2813 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Locations View 151-5 Page 673 P0715 - P0719: Testing and Inspection P0717 Torqshift For diagnosis of code P0717 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9531 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 8210 Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Front Door Latch Removal Note 1. Disconnect the exterior door handle actuating rod. 2. Disconnect interior door handle actuating cable from the latch. Item 6: Door Ajar Switch Removal Note 1. Remove the door ajar switch. 1 Lift the locking tab at the lower end. 2 Rotate the door ajar switch counterclockwise. 3 Remove the door ajar switch. Item 10: Exterior Door Handle Removal Note Page 3872 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Page 7718 5. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the safety belt buckle pretensioner wires. 6. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area so that moveable parts do not contact the support surface. 7. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly. 8. Deploy the safety belt buckle pretensioner by touching the other ends of the two wires to the terminals of a 12-volt battery. 9. To allow for cooling, wait at least ten minutes before approaching the deployed safety belt buckle pretensioner. 10. Dispose of the deployed safety belt buckle pretensioner in the same manner as any other part to be scrapped. Page 9056 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Auxiliary Relay Box Page 2110 View 151-13 Page 7359 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 8810 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 4960 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7631 REAR SAFETY BELT - BENCH SEAT, SECOND ROW Torx Bit, Safety Belt Bolt SPECIAL TOOL(S) REMOVAL WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. NOTE: Rear seats and trim panels removed for clarity. Right side shown, left side similar. 1. To access the second row outboard safety belt retractor, remove the quarter trim panel. Page 1005 Inspection System Diagnosis P1630 - P1634: Testing and Inspection For diagnosis of code P1633 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 30 P0040 - P0044: Testing and Inspection P0041 For diagnosis of code P0041 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - System Diagnosis P0760 - P0764: Testing and Inspection For diagnosis of code P0762 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6687 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Page 4240 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Restraints - Seat Belt Stop Button Service Seat Belt: Technical Service Bulletins Restraints - Seat Belt Stop Button Service TSB 05-3-10 02/21/05 SAFETY BELT WEB STOP BUTTON SERVICE FORD: 2000-2004 Mustang 2000-2005 Crown Victoria, Focus, Taurus 1999-2005 F-Super Duty 2000-2003 Windstar 2000-2005 Excursion, F-150, Ranger 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2002-2005 Explorer 2003-2004 Expedition 2004-2005 Freestar 2005 Escape Hybrid LINCOLN: 2000-2005 LS, Town Car 2003-2004 Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2001-2005 Mariner 2002-2005 Mountaineer 2004-2005 Monterey ISSUE To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available. ACTION Install the safety belt button kit, DO NOT replace the entire safety belt assembly. Follow the Service Procedure in the Instruction Sheet that comes with the kit. Refer to Section 501-20A of the appropriate model year Workshop Manual for additional information if needed. NOTE ONE KIT WILL REPAIR ONE SEAT BELT BUTTON. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 70611B09 42 Disclaimer Page 7795 Seat Occupant Sensor: Vehicle Damage Warnings CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Make sure the seat is completely assembled before rezeroing. Page 6923 View 151-12 Output Shaft Speed Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed Sensor OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (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 generated. Page 5706 Part 3 Of 3 Specifications Brake Bleeding: Specifications Bleeder screws .................................................................................................................................... ........................................................ 10 Nm (7 ft. lbs.) Page 6717 Steering Gear: Service and Repair Disassembly and Assembly Steering Gear Special Tool(s) 1. Remove the steering gear. 2. Drain any excess power steering fluid from the steering gear and then clean the exterior of the gear using a suitable solvent. Part 1 Of 2 Part 2 Of 2 3. Disassemble the parts in the order indicated in the following illustration and table. Page 8436 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Service Precautions Heater Core: Service Precautions WARNING: - Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. - The heater core inlet hose will become too hot to handle if the system is working correctly. Page 237 Inspection Testing and Inspection Micro ISO Relay: Testing and Inspection Page 2426 Page 725 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0743 refer to chart Part 3 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 8740 Page 9194 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 Page 647 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4096 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 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 such as the Compression Tester 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 five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Part 1 0f 2 Part 2 Of 2 Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Page 6602 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 6494 Page 781 P0770 - P0774: Testing and Inspection P0773 For diagnosis of code P0773 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5140 Item 7: Selector Lever Indicator Cable Removal Note 1. Position the selector lever indicator cable aside. 1 Loosen the screw. 2 Disconnect the cable. 3 Position the selector lever indicator cable aside. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 1619 Page 7173 Blower Motor Relay: Testing and Inspection Front blower motor relay Page 9360 Marker Lamp: Connector Views Page 9344 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity Without Auxiliary Climate Control ........................................................................................................ ....................................................... 36 oz (1.50 kg) With Auxiliary Climate Control ............................................................................................................. ....................................................... 53 oz (1.59 kg) Specifications Brake Bleeding: Specifications Bleeder screws .................................................................................................................................... ........................................................ 10 Nm (7 ft. lbs.) Page 3022 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 1594 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 2992 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4. Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a A/C service center to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following the automatic refrigerant charging meter operating instructions. 3. Charge the refrigerant system following the automatic refrigerant charging meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select A/C operation and allow the refrigerant charge to complete. Page 7570 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 9728 Page 4815 4. Remove the parts in the order indicated in the illustration and table. Item 3: Fuel Tube Spring Lock Coupling Removal Note 1. Install the special tool. Page 3760 Page 119 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Auxiliary Relay Box Description and Operation Transmission Shift Position Indicator Lamp: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP The transmission control indicator lamp (TCIL) is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to Transmission Control Switch in Hardware PCM Inputs. Page 2310 Headlamp Switch: Service and Repair HEADLAMP SWITCH REMOVAL CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch assembly. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5340 4. Remove the parts in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. 6. Fill the transmission with the specified quantity of the specified lubricant. Item 1: Front Axle Wheel Hub Retainer Removal Note 1. CAUTION: The front axle wheel hub retainer is a torque prevailing design nut. Do not reuse this nut. Remove the retainer and washer. ^ Insert a steel rod in the brake disc to prevent the halfshaft from turning while removing the retainer. Page 6365 P0355 P0355 - P0359: Testing and Inspection P0355 For diagnosis of code P0355 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 856 P0975 - P0979: Testing and Inspection P0979 For diagnosis of code P0979 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 3365 Item 22: Upper Intake Manifold Removal Note 1. Disconnect the four engine harness pin type retainers. 2. Disconnect the two engine harness pin type retainers. Item 21: Upper Intake Manifold Bolt Installation Note Upper Intake Manifold Torque Sequence 1. Tighten the upper intake manifold bolts in two stages in the sequence shown. - Tighten the bolts to 6 Nm (53 inch lbs.). - Tighten the bolts to 10 Nm (89 inch lbs.). Item 17: Spark Plug Wire Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and ignition coil. Page 9576 Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Page 4858 Inertia Fuel Shutoff Switch: Service Precautions WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. Page 8756 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH REMOVAL 1. Remove the door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4393 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Page 9379 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 Page 2054 Page 9133 Mechanical Returnless Fuel Pump Module (FPM) Page 3284 13. Install the special tool between the fuel supply line and the fuel supply manifold. Page 8422 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 3267 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley and Crankshaft Seal Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the accessory drive belt. Engine Controls, A/T - Various Driveability Issues/DTC's Cowl: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 8934 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 8694 View 151-17 Page 677 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0718 refer to chart Page 7448 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor (OCS) system is found only on the front passenger seat. The front passenger seat OCS system is comprised of a silicone gel-filled bladder mounted in the seat cushion, a pressure sensor that is mounted to the seat frame and an electronic control unit which is also mounted to the seat frame. Pressure is applied to the OCS system bladder when weight of any occupant or object in the front passenger seat is present. The pressure is then transferred through a tube, is sensed by the OCS system pressure sensor, then electronically communicated to the OCS system electronic control unit (ECU). Based on preprogrammed set points the OCS system ECU will inform the restraints control module (RCM), via a high-speed controller area network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module and passenger safety belt pretensioner are to be deployed in the event of a deployable collision. The RCM may also use this information to illuminate/not illuminate the passenger air bag deactivation (PAD) indicator. When an OCS system fault is present, the air bag indicator lamp will illuminate or the air bag warning chime will be activated (if an air bag indicator fault is present). The SRS then defaults the passenger air bag module to ON (activated) regardless of the size of the occupant in the front outboard passenger seat. The OCS system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. OCS system components are not to be installed separately. If installing a new OCS system, OCS system component or seat cushion foam pad, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. The OCS system also interprets a variable voltage signal provided by the safety belt tension sensor to identify the presence of a child safety seat in the front outboard passenger seat. The OCS system then communicates with the restraints control module (RCM), automatically deactivating the passenger air bag module and passenger safety belt pretensioner. Refer to Safety Belt Tension Sensor. Page 3720 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 645 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 901 P1110 - P1114: Testing and Inspection P1114 For diagnosis of code P1114 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3396 Oil Pressure Sender: Service and Repair CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the generator. 2. Remove the accessory drive belt idler pulley. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Items 3-5: Generator Mounting Bracket Removal Note 1. NOTE: Clearance between the engine and vehicle frame is limited. The A/C compressor mounting bracket brace, two long bolts, and generator mounting bracket should be removed from the engine as an assembly. Page 9188 Symbols Part 3 Auxiliary Blower Motor Relay Locations View 151-6 Page 7710 Page 3600 Heater Core: Testing and Inspection HEATER CORE WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require the installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. CARRY OUT a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Heater Core - Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot: - the thermostat may not be working correctly. Heater Core - Pressure Test Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater hoses with water and install the two plugs BT-7422-B and the adapter BT-7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater hoses with plug and adapter to the core tubes. Then connect the Pressure Test Kit to the adapter. Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Page 3431 3. Using the special tools, install the crankshaft front seal. Item 8: Crankshaft Pulley Installation Note 1. Lower the RH side of the subframe 50.8 mm (2 inch) - Remove the bolts. - Lower the subframe. 2. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley. Using the special tool, install the crankshaft pulley. 3. Raise the subframe into position, then install the bolts. 4. Connect the RH front anti-lock brake wheel sensor electrical connector. System Diagnosis P0310 - P0314: Testing and Inspection For diagnosis of code P0310 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1625 Page 4403 Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: 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 VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, 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 L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. For Ford L-M technician's, check out the "Programmable Module Installation" link on the Professional Technician Society (PTS) web sight for quick Programmable Module data information by vehicle when using WDS or NGS. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need 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. Page 4267 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Page 341 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2298 Page 1675 Page 7289 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 8510 Page 3488 3. If removing the ignition coil, remove the wiper motor and pivot assembly. 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Page 7061 Expansion Block/Orifice Tube: Description and Operation EVAPORATOR CORE ORIFICE TUBE NOTE: A new evaporator core orifice tube should be installed whenever a new A/C compressor is installed. The A/C evaporator core orifice has the following characteristics: - It is color-coded orange. - It is located in the condenser to evaporator line. - It has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the evaporator core orifice tube. - O-ring seals on the evaporator core orifice tube prevent the high-pressure liquid refrigerant from bypassing the evaporator core orifice tube. - It can be accessed through a fitting in the condenser to evaporator line. - Adjustment or service cannot be carried out to the evaporator core orifice tube. A new evaporator core orifice must be installed. Page 2909 Page 184 P0155 - P0159: Testing and Inspection P0158 For diagnosis of code P0158 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: All Technical Service Bulletins Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 486 P0410 - P0414: Testing and Inspection P0412 For diagnosis of code P0412 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6452 Page 6251 Page 9306 Page 2552 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 6379 Page 1398 P2005 - P2009: Testing and Inspection P2007 For diagnosis of code P2007 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9550 Symptom Chart Page 9298 High Beam Relay: Testing and Inspection Specifications Firing Order: Specifications 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 switch1 causing the magnetic field to collapse inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 6-tower, 6-tower horizontal and series 5 6-tower models (Freestar/Monterey/F 150 Heritage 3.9/4.2L). 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. 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. Page 611 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection A/T - 4F50N No 1-2 Upshift/DTC P0732 Set Clutch: All Technical Service Bulletins A/T - 4F50N No 1-2 Upshift/DTC P0732 Set TSB 04-17-10 09/06/04 4F50N TRANSAXLE NO 1-2 UPSHIFT AND DTC P0732 FORD: 2004-2005 Taurus, Freestar MERCURY: 2004-2005 Sable, Monterey This article supersedes TSB 04-15-12 to update the vehicle model years. ISSUE Some 2004-2005 Taurus/Sable and Freestar/Monterey vehicles, may exhibit a diagnostic trouble code (DTC) P0732 and a no 1-2 upshift condition. This may be due to an intermediate clutch piston seal becoming torn or loose (de-bonded) from the piston. ACTION To service, perform normal diagnosis per Workshop Manual. If the cause is determined to be internal to the transaxle, inspect the intermediate clutch piston seal. The outer clutch seal is bonded to the piston. If the seal is torn or loose replace the piston. Inspect the intermediate clutch plates and replace if necessary. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7E005 D8 Disclaimer Page 2844 1. Remove the accessory drive belt. - Rotate the accessory drive belt tensioner counterclockwise. - Push the spring clip towards the belt tensioner to lock the accessory drive belt tensioner in place. Item 1: Accessory Drive Belt Installation Note 1. Install the accessory drive belt. - Position the accessory drive belt onto the engine. - Rotate the accessory drive belt tensioner counterclockwise until spring clip releases. Page 4918 Fuel Temperature Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7548 Air Bag Control Module: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. Page 6674 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. P0106 P0105 - P0109: Testing and Inspection P0106 For diagnosis of code P0106 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7511 P0460 P0460 - P0464: Testing and Inspection P0460 For diagnosis of code P0460 refer to chart P0400-P0462 NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 603 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0603 refer to chart Page 3815 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7577 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Page 3282 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Power Window Switch, RH Side Front Page 5967 Page 2830 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 3062 Note: The bussed electrical center is located in the engine compartment. Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 6109 Page 4515 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The heated oxygen sensor (HO2S) (Figure 38) 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 temperatures of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will turn on the heater by providing the ground when the proper conditions occur. Since model year 1998 a high power HO2S heater and heater control system have been installed on the Stream 1 HO2S sensors of most vehicles. The high power heater reaches closed loop fuel control temperatures faster, which allows closed loop engine operation sooner. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Page 3382 Page 2508 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System Inertia Fuel Shutoff (IFS) Switch Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 87) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Reset RESET INSTRUCTIONS 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). 4. Turn key to on or start position for a few seconds, then off again. 5. WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. Again, check for leaking natural gas. Page 9669 Page 9434 Page 6643 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 1064 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1276 refer to chart Page 5074 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 1704 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Removal and Installation Impact Sensor: Service and Repair Removal and Installation Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Diagrams Trunk / Liftgate Latch: Diagrams Page 9684 14. Reconnect the 2 rear window defrost electrical connectors. Page 4181 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 Page 6272 Disclaimer Output Shaft Speed (OSS) Sensor Page 1368 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1723 Page 4106 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 2740 Powertrain Control Module (PCM) Reset Engine Control Module: Service and Repair Powertrain Control Module (PCM) Reset POWERTRAIN CONTROL MODULE (PCM) RESET Description All OBD II scan tools support the powertrain control module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. For more information about a drive cycle, refer to Drive Cycles. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Drive Cycles The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. Resetting Keep Alive Memory (KAM) Resetting Keep Alive Memory will return PCM memory to its default setting. Adaptive learning contents such as idle speed, refueling event, and fuel trim are included. A PCM Reset (described above) is also part of a KAM Reset. Both can be useful in post repair retest. After Keep Alive Memory has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. This function may not be supported by all scan tools. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Service Precautions Heater Core Case: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Page 8726 Page 4471 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 8753 Page 7696 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Page 3263 Item 1: Block Heater Electrical Connector Installation Note 1. Make sure that the block heater wiring is routed and secured away from rotating or hot components or damage to the wiring can occur. Removal and Installation Suspension Strut / Shock Absorber: Service and Repair Removal and Installation Shock Absorber and Spring Assembly - Front NOTE: Make sure the steering wheel is in the unlocked position. NOTE: Use the hex holding feature to prevent the studs from turning while removing or installing the stabilizer bar link nuts. 1. With the vehicle in NEUTRAL, position on a hoist. Part 1 Of 3 Part 2 Of 3 Page 6285 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Page 7636 Part 1 Page 1730 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Locations View 151-22 Page 687 For diagnosis of code P0721 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0766 P0765 - P0769: Testing and Inspection P0766 For diagnosis of code P0766 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 849 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4530 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Page 6175 Page 6466 Page 1153 P1460 - P1464: Testing and Inspection P1461 For diagnosis of code P1461 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3967 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Accessories - Trailer Tow Harness Kit Service Tip Trailer Adapter Kit: Technical Service Bulletins Accessories - Trailer Tow Harness Kit Service Tip Article No. 03-24-2 12/08/03 ELECTRICAL - TRAILER TOW SERVICE KIT - SERVICE TIP FORD: 1999-2003 WINDSTAR 2004 FREESTAR MERCURY: 2004 MONTEREY ISSUE For the 1999-2003 Windstar and 2004 Freestar/Monterey vehicles, due to changes in vehicle wiring, trailer tow wiring harnesses must be ordered based on the vehicle build date. Should a vehicle exhibit a trailer tow wiring concern, rather than diagnosing and/or repairing, order and install a replacement harness service kit. If a customer wishes to have trailer tow wiring installed on their vehicle, order the proper wiring kit. Do not attempt to install and modify trailer tow wiring that is not specified for the vehicle. This will lead to unnecessary work and possible failures. ACTION The correct service kit must be ordered according to the vehicle build date, as outlined in this TSB. Refer to the part information chart for application and correct service kit. SERVICE TIP WIRING CHANGES April of 2002: The connector from the trailer tow/reverse park aid harness (15k867) to the main body harness was changed to a water sealed connector. December of 2002: The circuits for the electric trailer brake were eliminated resulting in a change to the water sealed connector. Provisions for an electric brake are in all service kits. Circuitry for electric brakes are not present in vehicles built after 12/02/2002. 2004 Model Year: Dealer installed trailer tow kits will include a harness, three relays and two fuses. The relays and fuses are to be installed in the under hood fuse box bussed electrical center (BEC). The harness mates with a connector on the underside of the vehicle rearward of the spare tire. Replacing harnesses and removing interior trim is no longer required. Circuitry for electric trailer brakes are not included in the vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Locations Page 3664 Water Pump: Service and Repair REMOVAL AND INSTALLATION Special Tools And Equipment Special Tool(s) Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the accessory drive belt. Page 6391 Page 8752 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 6240 Page 9745 Windshield Washer Pump: Service and Repair WINDSHIELD WASHER PUMP AND RESERVOIR REMOVAL 1. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. CAUTION: Do not make any electrical connections prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Disconnect the battery. 2. Remove the RF front wheel. 3. Position the RF splash shield aside. Auxiliary Relay Box Page 4625 Leak Detection Valve: Service Precautions WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Page 6290 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 8087 Page 4757 13. Install the special tool between the fuel supply line and the fuel supply manifold. Page 7417 Page 9297 Page 2895 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Page 8138 Left Front Page 243 P0190 - P0194: Testing and Inspection P0193 OBD II - Base Gasoline For diagnosis of code P0193 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5403 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Page 877 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7558 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Locations View 151-16 Page 9557 Test W10-W11 Page 5852 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 4338 Throttle Plate Controller Check Operation The purpose of the TPPC is to control the throttle position to the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle signal. The TPPC interprets the duty cycle signal as follows: 0% <= DC < 5% - Out of range, limp home default position. - 5% <= DC < 6% - Commanded default position, closed. - 6% <= DC < 7% - Commanded default position. Used for key-on, engine off. - 7% <= DC < 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - 10% <= DC <= 92% - Normal operation, between 0 degrees (hard-stop) and 82%, 10% duty cycle = 0 degrees throttle angle, 92% duty cycle = 82 degrees throttle angle. - 92% < DC <= 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - 96% < DC <= 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate to be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The "H" driver is capable of positive or negative voltage to the Electronic Throttle Body Motor. Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The malfunction indicator lamp (MIL) (Figure 17) alerts the driver that the powertrain control module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Charts - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Page 3938 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 1297 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1713 refer to chart Page 9522 92-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 6524 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Page 7178 Page 4756 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Service and Repair Seals and Gaskets: Service and Repair Front Axle Halfshafts, Bearings and Seals Special Tool(s) Material 1. With the vehicle in NEUTRAL, position on a hoist. 2. Remove the front wheel and tire assembly. 3. CAUTION: Remove or tape the brake pads to prevent them from falling out of the anchor plate. CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose. NOTE: Remove the front brake anti-lock sensor harness from the clip. Remove the bolts and position the disc brake caliper aside. Page 1796 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 4435 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Seat Weight Pressure Sensor Page 5753 ^ Enter claims using Direct Warranty Entry (DWE). ^ Refund or 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 approval from Special Service Support Center. ^ "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES [NEW] PARTS REQUIREMENTS / ORDERING INFORMATION Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. RECALL PARTS SUPPORT CENTER The Recall Parts Support Center can be contacted via: ^ Phone ^ FAX Please be prepared to provide the following information: ^ Dealer Name and P & A code ^ Contact Name ^ Phone number and E-mail address ^ FSA # : 04S24 ^ Vehicle Identification Number (if requested) DEALER PRICE For latest prices, refer to DOES II. PARTS RETENTION AND RETURN Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures". EXCESS STOCK RETURN Service Precautions Air Bag Deactivation Indicator: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Technician Safety Information Seat Occupant Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes at the beginning of the removal procedure. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - Do not separate components. Page 1575 Seat Weight Pressure Sensor Page 91 P0110 - P0114: Testing and Inspection P0114 For diagnosis of code P0114 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1802 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) Malfunction Indicator Lamp (MIL) Check Engine, Service Engine Soon Or ISO Standard Engine Symbol The malfunction indicator lamp (MIL) (Figure 17) alerts the driver that the powertrain control module (PCM) has detected an OBD II emission-related component or system fault. When this occurs, an OBD II Diagnostic Trouble Code (DTC) will be set. - The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE SOON or ISO standard engine symbol (Figure 18). - Power is supplied to the MIL whenever the ignition switch is in the RUN or START position. - The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster proveout for approximately 4 seconds. - If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present. - The instrument cluster will illuminate the MIL if the PCM does not send a control message to the instrument cluster. - The PCM is operating in the Hardware Limited Operation Strategy (HLOS). - The MIL circuit is shorted to ground. - If the MIL remains off (during the bulb check): Bulb is damaged. - MIL circuit is open. - To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three consecutive drive cycles must be completed without a fault. - For any MIL concern, go to Symptom Charts. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptom Charts - If the MIL blinks at a steady rate, a severe misfire condition could possibly exist. - If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low. Page 21 P0020 - P0024: Testing and Inspection P0021 For diagnosis of code P0021 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5629 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 512 Inspection Page 7270 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Page 6560 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Page 1779 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Accessory Delay Relay 1 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 1 Page 3592 Part 2 Of 2 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 7: Radiator Alignment Pins Removal Note 1. Tie the radiator and the condenser to the upper radiator support using mechanics wire. ^ Allow 2 inches of slack in the condenser wire to allow for movement. ^ Remove the radiator alignment pins. Item 13: Transmission Cooler Tubes Removal Note Page 9127 Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 9482 View 151-10 P0315 P0315 - P0319: Testing and Inspection P0315 For diagnosis of code P0315 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Service Precautions Ignition Cable: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 2184 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 2: Speed Control Deactivator Switch Removal Note 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Remove the speed control deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. Item 2: Speed Control Deactivator Switch Installation Note 1. After the deactivator switch is installed, it is necessary to bleed the brake system. Page 9683 or repair surface as necessary. 5. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 to dry. 6. If reinstalling the original liftgate window glass, remove any excess urethane adhesive. 7. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. If installing a new liftgate window glass, apply urethane glass prep twice around the glass surface to be prepped. 8. If installing a new liftgate window glass, apply urethane glass prep to the same area that was prepped in the previous step. Allow 5 minutes to 10 minutes to dry. 9. If equipped, install Norton Foam Sealant 565 Black Foam Tape to the pinch weld area. 10. Cut the urethane adhesive applicator tip to specification. 11. Apply a bead of urethane adhesive to the liftgate door glass on the primed area. 12. CAUTION: Open the windows to prevent the rear window glass from being pushed out by air pressure if a door is closed. Install the liftgate window glass. After the glass is set, check for water leaks and add urethane adhesive where needed. 13. Install the rear wiper motor. Page 3032 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 2908 The power steering lines can be accessed from behind the rear of the subframe crossmember. See Figure 3. A) First, firmly PUSH the line into the fitting. If the line was not fully engaged, it may make a "click" noise when you PUSH on it. B) PULL the line away from the fitting to ensure full engagement. C) If the line comes out of the fitting, reinsert it, then repeat steps A through C. Check the power steering fluid level, fill if necessary and check for leaks. D) Repeat steps A through C on the other line. 4. Install the 8 mm bolt. Tighten the bolt to 6 Nm (53 lb-in). 5. Lower the vehicle. Page 9329 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 Page 7149 Part 2 1. Refer to the chart for refrigerant oil adding amounts and methods of installation. Refrigerant Oil Adding for New A/C Compressor Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), add the same amount plus the amount collected during refrigerant recovery. - If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 ounces), add the same amount plus the amount collected during refrigerant recovery. - If the amount of oil drained from the old A/C compressor is less than 85 ml (3 ounces), add 85 ml (3 ounces) plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation 1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2 ounces). Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector along with the refrigerant oil. 1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct adapters to match the amount of PAG oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. Page 5232 2. Using the special tool, remove the LH differential seal. 1 Rotate the special tool. 2 Rotate the forcing screw while holding the front cover seal remover. 3 Remove the metal protector from the LH differential seal and remove protector from tool. Item 2: LH Rubber Seal Portion Removal Note 1. Using the special tool, remove the rubber portion of the LH differential seal. 1 Install the special tool into left differential seal and rotate the special tool. 2 Rotate the forcing screw while holding the special tool. 3 Remove the rubber portion of the seal. Item 3: RH Metal Seal Protector Removal Note 1. Install the special tools into the RH differential seal. 2. Using the special tool, remove the RH differential seal metal protector. Page 3586 Page 8033 Page 7139 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM EVACUATION AND CHARGING Special Tool(s) SPECIAL TOOL(S) Refrigerant System Evacuation Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Service Precautions Ignition Cable: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 1109 Inspection Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. P0480 P0480 - P0484: Testing and Inspection P0480 For diagnosis of code P0480 refer to chart P0463-P0503 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4600 Diagnostics/Evaporative Emission Repair Verification Drive Cycle Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Page 5115 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 8940 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 Page 9058 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 1652 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 1 P2700 P2700 - P2704: Testing and Inspection P2700 For diagnosis of code P2700 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2630 2. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 17: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 18: Electrical Connector Removal Note 1. Disconnect the occupant classification sensor and remove any retainers from its wiring harness. Item 21: Occupant Classification Sensor (OCS) Removal Note Page 7727 Special Tool(s) Page 7806 system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. 4. CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 7726 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Install the driver seat. Do not reactivate the supplemental restraint system as instructed to do so in the seat removal and installation procedure at this time. - After installation, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket or the wire harness do not come in contact with any other part of the seat that may cause damage. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 7. Connect the battery ground cable. 8. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 2747 Locations View 151-5 Page 7541 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Bussed Electrical Center (BEC) Fuse: Application and ID Bussed Electrical Center (BEC) Page 415 P0325 - P0329: Testing and Inspection P0326 For diagnosis of code P0326 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 612 P0605 - P0609: Testing and Inspection P0606 OBD II - Base Gasoline For diagnosis of code P0606 refer to the following: - Vehicles with Electronic Throttle Control (ETC) refer to NOTE 13. - All other vehicles refer to NOTE 12. NOTE 12: Be sure to check for aftermarket performance products before replacing the PCM. If replacement is necessary refer to Flash Electrically Eraseable Programmable Read Only Memory. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning NOTE 13: DTC is an indication of a failure mode in the Electronic Throttle Control system, which includes the APPS, ETB, and PCM. It is accompanied by other DTCs which provide repair direction. Proceed to Trouble Code Indexes to repair those DTCs, and the P0606 will not be reset. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0606 refer to chart Page 3709 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 1991 Parking Assist Distance Sensor: Diagrams Page 9052 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 8345 P1460 P1460 - P1464: Testing and Inspection P1460 For diagnosis of code P1460 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 36 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 579 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Battery - Battery Eye Function/Charging/Service Battery: Technical Service Bulletins Battery - Battery Eye Function/Charging/Service TSB 07-5-8 03/19/07 BATTERY SERVICE - OPERATION OF BATTERY EYE - CHARGING SERVICE TIPS FORD: 1999-2003 Escort 2000-2006 Taurus 2000-2007 Crown Victoria, Focus, Mustang 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 2000-2003 Windstar 2000-2004 Explorer Sport 2000-2006 Excursion 2000-2007 E-Series, Expedition, Explorer, F-150, F-250 Light Duty, F-53 Motorhome Chassis, F-Super Duty, Ranger 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004-2006 Freestar 2005-2007 Escape Hybrid 2007 Edge 2000-2007 F-650, F-750 2006 Low Cab Forward LINCOLN: 1998-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2002 Blackwood 2003-2005 Aviator 2006-2007 Mark LT, Mark LT 2007 MKX MERCURY: 1999-2002 Cougar 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2002 Villager 2000-2007 Mountaineer 2004-2006 Monterey 2004-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 06-4-2 to update the vehicle model years. ISSUE This TSB describes the operation and function of the Battery Eye and correct Battery Recharging procedures. ACTION Refer to the following Service Tips to avoid misdiagnosis of a battery using the Battery Eye, and to determine the best way to charge a battery that may be discharged. SERVICE TIPS Battery Eye Operation / Function Page 8178 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Application and ID Turn Signal Flasher: Application and ID The Flasher function for this vehicle is provided by the Smart Junction Box (SJB). Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Specifications Firing Order: Specifications 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 switch1 causing the magnetic field to collapse inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 6-tower, 6-tower horizontal and series 5 6-tower models (Freestar/Monterey/F 150 Heritage 3.9/4.2L). 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. 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. Page 66 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1633 Page 614 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 5094 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 1071 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1337 P1745 - P1749: Testing and Inspection P1747 For diagnosis of code P1747 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 4266 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Page 3735 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 8985 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 1924 Special Tool(s) Page 1063 P1275 - P1279: Testing and Inspection P1276 OBD II - Base Gasoline For diagnosis of code P1276 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4537 Page 6617 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Page 9096 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 8106 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 Page 6479 Page 4130 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 4252 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 8939 Cigarette Lighter: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 3639 Page 6219 Page 6076 Starter Motor: Diagrams Service Precautions Front Door Hinge: Service Precautions CAUTION: - For correct sliding door operation, it is critical that the door adjuster wedge and striker on the body pillar fit smoothly into the wedge pocket and latch in the power sliding door. If any of the adjustments are made, realignment of the striker may be necessary. - Do not swing the door open more than twenty-five degrees or damage to the other hinges may occur. Page 78 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2057 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH REMOVAL 1. Remove the door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5147 Item 7: Selector Lever Indicator Cable Removal Note 1. Position the selector lever indicator cable aside. 1 Loosen the screw. 2 Disconnect the cable. 3 Position the selector lever indicator cable aside. Page 6768 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 5091 Spark Plug: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 4514 Page 9222 Left Front Page 9513 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 8689 119-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 3473 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Page 7928 Parking Assist Distance Sensor: Locations View 151-4 Page 1414 P2065 - P2069: Testing and Inspection P2066 For diagnosis of code P2066 refer to NOTE 7: NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7278 Special Tool(s) Page 8557 Page 8461 1. To install, reverse the removal procedure. Page 3007 Brake Bleeding: Service and Repair Brake System Bleeding Special Tool(s) Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the diagnostic tool cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool instructions. 2. Clean all the dirt from the area and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. Service Precautions Ignition Cable: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Interior - Under Column Access Door Warped/Broken Steering Column Cover: All Technical Service Bulletins Interior - Under Column Access Door Warped/Broken TSB 04-22-9 11/15/04 ACCESS DOOR WARPED OR BREAKING OFF FROM THE UNDERSIDE OF THE STEERING WHEEL SHROUD FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit the access door, located on the underside of the steering wheel shroud, being warped or breaking off. ACTION Replace the access door. The access door can now be serviced separately, it is no longer necessary to replace the entire steering wheel shroud. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE ACCESS DOOR HAS BEEN BROKEN OFF PROCEED TO STEP 2. 1. If the access door is being replaced due to warping, it must first be removed. Remove the door by repeatedly opening and closing the door. The molded hinge area of the door will fatigue and the door will break off leaving a clean edge. 2. Replace the access door with the correct color service part. 3. The new door must be slid into place, and will be held in place with the tabs on each side of the door. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042209A Replace Access Door On 0.2 Hr. The Steering Wheel (Includes Time To Remove The Old Door If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 3L518 01 Page 4090 Spark Plug: Service and Repair IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. If removing the ignition coil, remove the wiper motor and pivot assembly. Page 3058 Fuse: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 8505 Page 3846 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 1033 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-6 Page 834 Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7933 P0131 P0130 - P0134: Testing and Inspection P0131 OBD II - Base Gasoline For diagnosis of code P0131 refer to chart P0112-P0147 If there is no link in the chart then: Locations View 151-3 Diagrams Initial Inspection and Diagnostic Overview Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION NOTE: - Some vehicles are equipped with adjustable brake and accelerator pedals. These pedals are serviced as an assembly. - Care should be exercised when carrying out service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to make sure of correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Page 3995 Page 2624 OCS system. Attach the seat cushion trim cover J-clips to the seat cushion pan. Item 12: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 15: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 16: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Page 4174 Symbols Part 4 Page 473 Inspection Page 918 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Connector Views Fuse Block: Connector Views Bussed Electrical Center (BEC) Page 9377 Symbols Part 5 Page 8532 Locations View 151-16 Page 9533 Symbols Part 2 Page 867 P0980 - P0984: Testing and Inspection P0983 For diagnosis of code P0983 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 937 P1130 - P1134: Testing and Inspection P1131 For diagnosis of code P1131 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 2330 View 151-5 Page 4118 Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two design types of IAT sensors used, a stand alone\non-integrated type (Figure 39) and a integrated (Figure 40) 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. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A non-integrated screw in type (Figure 39) and an integrated type, which is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 48). The TMAP sensor consists of a IAT thermistor and a manifold absolute pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation found later. Page 6397 Multiple Junction Connector: Diagrams C316-C3206 Page 6128 Smart Junction Box (SJB) Page 2933 The power steering lines can be accessed from behind the rear of the subframe crossmember. See Figure 3. A) First, firmly PUSH the line into the fitting. If the line was not fully engaged, it may make a "click" noise when you PUSH on it. B) PULL the line away from the fitting to ensure full engagement. C) If the line comes out of the fitting, reinsert it, then repeat steps A through C. Check the power steering fluid level, fill if necessary and check for leaks. D) Repeat steps A through C on the other line. 4. Install the 8 mm bolt. Tighten the bolt to 6 Nm (53 lb-in). 5. Lower the vehicle. Brake Pedal Position Switch View 151-11 Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Description and Operation Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITORING SYSTEM (TPMS) Your vehicle may have a temporary spare tire. The temporary spare tire for your vehicle is labeled as such. It is smaller than a regular tire and is designed for emergency use only. Replace this tire with a full-size tire as soon as possible. Note: The Low Tire Pressure Warning system (if equipped) will detect the temporary spare tire and illuminate the low tire warning light until the spare tire is replaced with a proper full-size tire. Page 956 Inspection Page 1536 Parking Assist Control Module: Diagrams Page 2665 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 8076 Symbols Part 4 Page 1748 Page 7232 Clutch Cycling Orifice Tube Type Refrigerant System, Part 2 ABS - Module Replacement Service Tip Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 4470 Door Lock Actuator Assembly, Left Sliding Door View 151-21 P1715 P1715 - P1719: Testing and Inspection P1715 4R70W For diagnosis of code P1715 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 8993 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Page 4775 Page 4260 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Removal and Installation POWERTRAIN CONTROL MODULE (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7597 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Page 7596 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Page 487 Inspection Page 1441 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagrams Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 3911 1. Using the special tool, remove the HO2S and the catalyst monitor sensors. INSTALLATION 1. To install, reverse the removal procedure. Item 2: HO2S and Catalyst Monitor Sensors Installation Note 1. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S and the catalyst monitor sensors. Using the special tool, install the HO2S and the catalyst monitor sensors. Testing and Inspection Daytime Running Lamp: Testing and Inspection INSPECTION AND VERIFICATION NOTE: When installing a new smart junction box (SJB), it must be reconfigured for this feature, if originally equipped. Refer to Information Bus (Module Communications Network). 1. Verify the customer concern by operating the daytime running lamps (DRL) following these steps: 1 Place the ignition switch in the RUN position. 2 Place the headlamp switch in the OFF position. 3 If the DRL does not operate, make sure the SJB is configured for DRL before proceeding to the next step. 2. Verify the parking lamp operation. 1 Place the headlamp switch in the parking lamps ON position. If the parking lamps do not operate correctly, REFER to Parking Lamp. 3. Verify the high beam operation. 1 Place the headlamp switch in the headlamps ON position. 2 Place the multifunction switch in the high beam position. If the high beams operate correctly and the DRL operation is incorrect, INSTALL a new SJB. TEST the system for normal operation. If the high beams do not operate correctly, REFER to Headlamps for correct diagnosis. Page 1805 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 3565 Service Precautions Antenna, Radio: Service Precautions CAUTION: Be careful not to damage the grid line with the razor blade. If this occurs, additional repair may be necessary. Page 4827 Fuel Filler Hose: Service and Repair FUEL TANK AND FILLER PIPE Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard. NOTE: The fuel tank comes equipped with a composite protective shield mounted with the support straps and retainers on the right hand side of the fuel tank. Make sure the protective shield is installed correctly whenever the fuel tank is installed. 1. With vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel pressure. 3. Disconnect the battery ground cable. Page 8209 2. NOTE: - When a new lock cylinder is installed, the lock cylinders and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is to be used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. Page 7891 NOTE: All of the doors must be closed during the perimeter lighting programming procedure. 1. Turn the key to ON. 2. Press the UNLOCK button 3 times. 3. Turn the key to OFF. 4. Press the UNLOCK button 3 times. 5. Turn the key to ON. 6. Press the UNLOCK button, then press the UNLOCK button again. The horn will chirp once if the perimeter lighting feature was just deactivated or it will chirp twice (1 short chirp and 1 long chirp) if the perimeter lighting feature was just activated. 7. Turn the key to OFF. The horn will chirp to confirm the procedure is complete. Unlock Inhibit Programming NOTE: All of the doors must be closed during the unlock inhibit programming procedure. 1. Turn the key to ON. 2. Press the UNLOCK button 3 times. 3. Turn the key to OFF. 4. Press the UNLOCK button 3 times. 5. Turn the key to ON. 6. Press the LOCK button, then press the LOCK button again. The horn will chirp once if the unlock inhibit feature was just deactivated or it will chirp twice (1 short chirp and 1 long chirp) if the unlock inhibit feature was just activated. 7. Turn the key to OFF. The horn will chirp to confirm the procedure is complete. Page 6570 Thrust Angle ^ Rear thrust angle can be defined as a line bisecting rear toe or simply, the direction in which the rear wheels are pointed. ^ Rear thrust angle = (LR toe minus RR toe) / 2 ^ If the rear wheels are pointed to the right, thrust angle is positive; if the rear wheels are pointed to the left, thrust angle is negative. 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. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Shimmy Shimmy, as observed 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 observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe 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 hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, 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). Efforts 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 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 roadability problem, it is important to understand the difference between wander and poor groove feel. Low Tire Warning (LTW) System The Low Tire Warning (LTW) system detects differences in inflation pressures in one or more tires. The system uses the ABS wheel speed sensors to monitor the rolling radius of the wheel and tire assemblies. If a difference in rolling radius is detected, the ABS module illuminates the LTW lamp Page 3023 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 6584 Page 8102 Symbols Part 5 Electronic Manual Temperature Control Blower Motor Switch: Description and Operation Electronic Manual Temperature Control BLOWER MOTOR SWITCH The blower motor switch is mounted in the climate control assembly and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF. Page 7401 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 263 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2607 Page 228 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0183 refer to chart Page 1076 Inspection Page 7529 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Locations View 151-5 Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 31 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8951 44-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 3981 Fuel Temperature Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7603 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Page 453 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Auxiliary Relay Box Page 4193 which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Electronic Throttle Control System Strategy GEN II ETC System As stated earlier the torque based ETC strategy was developed mainly to improve fuel economy and to accommodate Variable Cam Timing. This is possible by not coupling the throttle angle to the drivers pedal position. By uncoupling the throttle angle (produce engine torque) from pedal position (driver demand). This allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. ETC is used on the 2004 MY Lincoln LS and Ford Thunderbird, Explorer/Mountaineer, and the new light-duty F-series. Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Never run the engine with one wheel off the ground, such as when changing a tire. The wheel still on the ground could cause the vehicle to move. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to lift the vehicle for any other purpose. Refer to the Owner Literature when using the jack supplied with the vehicle. - Under no circumstances should the vehicle ever be lifted by the front control arms, front I-braces, suspension arm brackets, rear stabilizer or differential housing. Severe damage to the vehicle could result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the following procedure. Jacking Points Jacking Points To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING CAUTION: - Do not allow the lift adapters to contact the steering linkage, suspension arms, front I-braces, stabilizer bar, or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the lift adapters prior to lifting the vehicle. - Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. - Do not lift the vehicle on the rocker panel pinch flange except at the designated lift points or body damage may occur. Lift the vehicle using the following procedure. Lifting Points-Drive-On Hoist Page 4171 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 7768 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Second Row, RH SIDE IMPACT SENSOR - SECOND ROW, RH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system Page 8016 Speaker: Service and Repair Door Speaker DOOR SPEAKER REMOVAL NOTE: The removal and installation procedures apply to all original-equipment, door-mounted speakers. 1. Remove the door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4564 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 2785 13. Install the special tool between the fuel supply line and the fuel supply manifold. Locations View 151-22 Page 9045 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 9280 Headlamp Dimmer Switch: Testing and Inspection Page 6588 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5846 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 2138 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor NOTE: When installing a new steering wheel rotation sensor, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration procedures. 1. Remove the parts in the order indicated in the following illustration and table. Page 895 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3747 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 8479 Keyless Entry Key-Pad: Description and Operation Keyless Entry Keypad The keyless entry keypad, located on the exterior of the driver door, provides a method for the customer to access their vehicle without a key or remote transmitter. The keyless entry keypad feature: locks all doors and liftgate while arming the perimeter alarm (if equipped). - unlocks only the driver door and disarms the perimeter alarm (if equipped). - unlocks all doors and liftgate. - programs/erases customer key code. - enables/disables autolocking. - opens/closes power sliding doors (if equipped). The keyless entry keypad feature operates independently of key position status, vehicle speed, or transmission position. When a keyless entry keypad button is pressed, the keyless entry keypad buttons illuminate to provide better visibility. If LOCK ALL DOORS is entered, or 5 seconds have elapsed since the last button press, the illumination is turned off. Each vehicle equipped with a keyless entry keypad is programmed with a 5-digit factory keyless entry keypad code. This code is provided to the customer through a wallet card in the owner literature package. In addition, this code is available through a diagnostic tool and is also printed on the SJB label. A personal keyless entry keypad code can be programmed into the SJB. When entering codes, each digit must be entered within 5 seconds of the prior digit. Anti-scan Feature If the wrong code has been entered 7 times (35 consecutive button presses), the keyless entry keypad will go into an anti-scan mode. This mode disables the keyless entry keypad for 1 minute and the keyless entry keypad lamp will flash. The anti-scan feature will turn off after: 1 minute of keyless entry keypad inactivity. - pressing the UNLOCK button on the remote transmitter. - the key is turned to the ON position. Unlocking the Doors and Liftgate with the Keyless Entry Keypad To unlock the driver door, enter either the factory set code or the personal code (each digit must be pressed within 5 seconds of the prior digit). The interior lamps will illuminate. To unlock all doors, enter either the factory set code or the personal code (driver door unlocks) and press the 3/4 control within 5 seconds. Opening and Closing the Sliding Doors with the Keyless Entry Keypad To open or close the sliding door, enter either the factory set code or the personal code (each digit must be pressed within 5 seconds of the prior digit) then press the 5/6 button for the driver side door or 9/0 for the passenger side door. Locking the Doors with the Keyless Entry Keypad It is not necessary to enter the factory set or personal code prior to locking all doors. To lock all doors, press the 7/8 and 9/0 controls at the same time. Central Locking/Unlocking The central locking/unlocking function is independent of the ignition switch and transmission range selector lever position. Central unlocking of all the doors is accomplished with: driver or passenger door lock control switches (unless the unlock inhibit feature is enabled). - two unlock commands from the remote transmitter within 3 seconds. - keyless entry keypad. Central locking of all doors is accomplished with: door lock control switches - lock command from the remote transmitter - keyless entry keypad (if equipped) When the vehicle is in an armed or full-alarm security state, any unlock command from the door lock control switches will be ignored if the unlock inhibit feature is enabled. The door lock control switches will be enabled if a valid unlock command has been received from the remote transmitter, keyless entry keypad, or the key is cycled to ON. Smart Junction Box (SJB) Additional Features The SJB can also be programmed to enable/disable the following features: perimeter lighting feature - unlock inhibit feature Perimeter Lighting Programming Page 4166 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 3406 Part 3 Of 3 To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. Page 3107 Page 2458 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 1859 Coil On Plug (COP) Ignition Coil: Description and Operation Coil On Plug (COP) COIL ON PLUG Coil On Plug The coil on plug (COP) (Figure 65) ignition operates similar to standard coil pack ignition except each plug has one coil per plug. COP has three different modes of operation: engine crank, engine running, and CMP Failure Mode Effects Management (FMEM). Gasoline Fuel System Fuel Pressure Sensor/Switch: Description and Operation Gasoline Fuel System FUEL RAIL PRESSURE SENSOR Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 36) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 37) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve 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. System Diagnosis P0875 - P0879: Testing and Inspection For diagnosis of code P0876 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 1078 Inspection Page 5452 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 3122 Page 3498 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 3736 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 8120 Test W4-W6 Electronic Manual Temperature Control Blower Motor Switch: Description and Operation Electronic Manual Temperature Control BLOWER MOTOR SWITCH The blower motor switch is mounted in the climate control assembly and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF. System Diagnosis P0430 - P0434: Testing and Inspection For diagnosis of code P0430 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6192 Page 6131 Page 1992 Trailer Tow Relay, Right Turn Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 509 P0450 - P0454: Testing and Inspection P0452 For diagnosis of code P0452 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1670 Control Module HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL EATC Module The EATC module: is located in the instrument panel. - has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs). - utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble codes (DTCs). These DTCs direct the technician to the inoperative component. - display will switch between Celsius and Fahrenheit when the instrument cluster display is toggled. Page 6168 Page 9182 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 349 P0265 - P0269: Testing and Inspection P0268 For diagnosis of code P0268 refer to chart B1219-B1317 / P0182-P1272 Page 2120 Page 235 Inspection Page 4317 1. Using the special tool, remove the HO2S and the catalyst monitor sensors. INSTALLATION 1. To install, reverse the removal procedure. Item 2: HO2S and Catalyst Monitor Sensors Installation Note 1. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S and the catalyst monitor sensors. Using the special tool, install the HO2S and the catalyst monitor sensors. Page 7464 Part 1 Page 5120 View 151-6 Page 830 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3559 Initial Inspection and Diagnostic Overview Trailer Lamps: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Verify the exterior lighting system of the vehicle is operating correctly. If not, refer to the appropriate pinpoint test. See: Pinpoint Tests 3. Visually inspect for obvious signs of mechanical or electrical damage. VISUAL INSPECTION CHART Electrical Bussed electrical center (BEC) fuse(s): 46 (20A) (trailer tow stop/turn) - 52 (20A) (trailer tow parking) - 58 (30A) - 62 (30A) - 65 (30A) - BEC - Circuity - Relay(s) - Bulb(s) 4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. 5. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 6. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 7. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - SCP, ISO or UBP circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for SJB, refer to Information Bus (Module Communications Network). - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the SJB. 8. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 9. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Page 3311 1. Remove the accessory drive belt. - Rotate the accessory drive belt tensioner counterclockwise. - Push the spring clip towards the belt tensioner to lock the accessory drive belt tensioner in place. Item 1: Accessory Drive Belt Installation Note 1. Install the accessory drive belt. - Position the accessory drive belt onto the engine. - Rotate the accessory drive belt tensioner counterclockwise until spring clip releases. Page 4817 Item 8: O-Ring Seal Installation Note 1. Lubricate the new O-ring seals with clean engine oil before installing. Item 3: Fuel Tube Spring Lock Coupling Installation Note 1. Align the fuel tube fittings and press together until an audible click is heard. Then, pull on the fittings to make sure they are fully engaged. Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - If removing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Seat Adjust Switch, Driver Side Front View 151-16 Page 1038 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1268 refer to chart P1477 P1475 - P1479: Testing and Inspection P1477 For diagnosis of code P1477 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1788 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 8156 Symbols Part 5 Page 4525 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Specifications Axle Nut: Specifications Note: Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut Axle nut ................................................................................................................................................ ................................................... 130 Nm (96 ft.lbs.) Page 3414 - Tighten the engine front cover studs to 7 Nm (62 inch lbs.). - Using a new gasket, install the coolant pump. - Tighten the fasteners in the sequence shown. Tighten bolt No. 12 to 10 Nm (89 inch lbs.). - Tighten all other fasteners to 28 Nm (21 ft. lbs.). 5. Install the two oil pan bolts and tighten to 10 Nm (89 inch lbs.). 6. Install the catalyst monitor sensor electrical connector bracket. 7. Connect the catalyst monitor sensor electrical connector. Item 9: Crankshaft Front Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation. Assemble the special tools, then place the crankshaft front seal onto the special tools. Page 7666 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 4453 View 151-13 Page 4563 P2110 P2110 - P2114: Testing and Inspection P2110 For diagnosis of code P2110 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9170 Page 2373 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 167 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4189 14-4 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 907 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8558 Page 3050 Locations View 151-6 Page 6235 Relay Box: Locations Bussed Electrical Center (BEC) Page 2158 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 4509 View 151-5 Page 7664 Page 8324 Part 1 Part 2 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 5: Secondary Hood Latch Release Cable Removal Note 1. Disconnect the secondary release cable from the hood latch. Item 7: Hood Latch Removal Note 1. Mark the hood latch prior to removal of the bolts. Item 8: Primary Hood Latch Release Cable Removal Note 1. Disconnect the primary release cable from the hood latch. - Release the cable locators. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Hood Latch Installation Note 1. When a hood latch is installed, the latch adjustment must be checked. Page 685 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0720 refer to chart Page 2874 Heater Hose: Service and Repair Removal and Installation AUXILIARY HEATER OUTLET AND INLET LINE REMOVAL 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Clamp off and disconnect the heater hoses at the front of the auxiliary heater inlet and outlet lines. 3. Remove the bolt and the front line bracket. 4. Remove the bolts and the two rear line brackets. Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 9729 Page 5660 P0151 P0150 - P0154: Testing and Inspection P0151 OBD II - Base Gasoline For diagnosis of code P0151 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5043 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 2025 Page 4848 Fuel Temperature Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2257 Mechanical Returnless Fuel Pump Module (FPM) Page 3084 Page 3626 1. Disconnect the fluid cooler tubes from the connector assembly. ^ Push the fluid cooler tube inward slightly, squeeze the retaining clip, and with a slight twisting motion, pull the fluid cooler tube out of the connector assembly. Item 15: Radiator Support Bolts Removal Note 1. Detach the power steering lines from both sides of the radiator lower support. 2. Remove the bolt and position the A C muffler bracket aside. Item 19: Radiator Removal Note 1. Lower the vehicle, cut the mechanic's wire and remove the radiator, cooling fans and shroud as an assembly. Page 5811 11. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to Specifications. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the master cylinder to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all the dirt from the area and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Page 5322 17. Remove the rear transaxle support insulator bracket. 18. NOTE: It will be necessary to lower the left side of the subframe to remove the main control cover through the wheel well. Remove the remaining bolts, and the main control cover. 19. CAUTION: Do not pull on the wires or the electrical connectors. Damage to the connectors will result. Lift the locking tab and disconnect the electrical connectors. 20. Position the transaxle wiring harness out of the way. Page 7697 Seat Belt Retractor: Service Precautions WARNING: After any vehicle collision, the safety belt system at all outboard seating positions (except driver, which has no "automatic locking retractor" feature) must be checked by a qualified technician to verify that the "automatic locking retractor" feature for child seats is still functioning properly, in addition to other checks for proper safety belt system function. A belt and retractor assembly must be replaced if the safety belt assembly's "automatic locking retractor" feature or any other safety belt function is not operating properly when checked according to the procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. Page 3383 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Page 864 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Removal and Installation Battery: Service and Repair Removal and Installation BATTERY REMOVAL 1. Disconnect the battery. Page 7996 Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 8629 Power Seat Switch: Testing and Inspection Seat Adjust Switch, Passenger Side Front Page 8292 1. Remove the power sliding door center track molding. 2. Close the power sliding door to approximately 100 mm (4 inches) from the B-pillar and remove the front cable. 1 Remove the clip. 2 Remove the front cable. 3. Open the power sliding door halfway and disconnect the rear cable. 1 Remove the rear clip. 2 Remove the rear cable. 4. Feed the front cable through the body to the interior of the vehicle. Item 6: Power Sliding Door Control Module Removal Note Page 9424 Horn Relay: Testing and Inspection Page 3517 Spark Plug: Service and Repair IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. If removing the ignition coil, remove the wiper motor and pivot assembly. Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 6310 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Page 2723 Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Front Camber and Caster Adjustment Alignment: Service and Repair Front Camber and Caster Adjustment Front Camber and Caster Adjustment 1. Remove the cowl top vent panel. 2. Center punch the four spot welds. 3. Loosen the nuts. 4. CAUTION: Do not cut deeper than necessary to remove the alignment plate. Using the special tool, remove the four spot welds. 5. Remove the nuts and the alignment plate. Description and Operation Front Subframe: Description and Operation FRONT SUBFRAME The front subframe is bolted to the body and is used to: aid in structural support. - provide mounting surfaces for the front suspension. - provide mounting points for the front stabilizer bar. - provide mounting for the engine. - provide mounting for the steering gear. - protect the transmission and oil pan from damage. Page 377 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1312 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6691 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 11 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9441 Page 4336 The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an Enhanced-Quizzer (E-Quizzer) processor. The primary monitoring function is performed by the Independent Plausibility Check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by specified amount, the IPC takes appropriate mitigating action. ETC System Failure Mode And Effects Management, Part 1 ETC System Failure Mode And Effects Management, Part 2 Since the IPC and main controller share the same processor, they are subject to a number of potential, common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate Failure Mode and Effects Management (FMEM) actions. Electronic Throttle Monitor Operation: Page 4172 Symbols Part 2 Page 1731 Relay Box: Locations Bussed Electrical Center (BEC) Page 5711 127-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 1316 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-9 Page 203 P0170 - P0174: Testing and Inspection P0174 OBD II - Base Gasoline For diagnosis of code P0174 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7456 Part 1 Part 2 Page 8100 Symbols Part 3 Page 866 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Specifications Idle Speed: Specifications Idle Speed is Computer Controlled Hot Idle ................................................................................................................................................ .............................................................. 700-730 rpm Page 423 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Auxiliary Relay Box Page 8651 1. Using a suitable tool, carefully pry the side shield for access to the recliner handle clip and remove the clip. Item 3: Pivot Handle Clip Disassembly Note 1. Access the pivot handle clip from the bottom side of side shield, and remove the clip. Item 17: Backrest-to-Cushion Bolt Disassembly Note 1. Removal of cushion release cables. 1 Release the RH cable end. 2 Release the RH cable from the anchor retainer. 3 Release the LH cable end. 4 Release the LH cable from the anchor retainer. Item 36: Seat Cushion Trim Cover Disassembly Note 1. Release the J-clips. 2. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam pad. Separate the hook and loop fasteners. Page 9355 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 7645 8. Deploy the safety belt buckle pretensioner by touching the other ends of the two wires to the terminals of a 12-volt battery. 9. To allow for cooling, wait at least ten minutes before approaching the deployed safety belt buckle pretensioner. 10. Dispose of the deployed safety belt buckle pretensioner in the same manner as any other part to be scrapped. Page 7724 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The power seat track seat position sensor is mounted at the outboard front of the seat track. The manual seat track seat position sensor is mounted at the LH front of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. 2. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or Page 1439 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 887 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3640 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 2 Page 160 P0145 - P0149: Testing and Inspection P0148 For diagnosis of code P0148 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7102 2. Fill the engine cooling system. Page 3812 Page 7513 Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT The fuel level input (FLI) is a hard wire signal input to the PCM from the fuel pump (FP) module. Refer to the description of the FLI in the On-Board Diagnostics II Monitors. Page 3408 4. Using the special tool, remove the crankshaft pulley. 5. Raise the subframe into position, then install the bolts. Item 9: Crankshaft Front Seal Removal Note 1. Using the special tool, remove the front crankshaft front seal. Item 11: Engine Front Cover Stud Bolt Removal Note 1. Disconnect the catalyst monitor sensor electrical connector. Electrical - ABS/TCS/Park Brake Lamps Flickering Wiring Harness: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 6992 Compressor Clutch Relay: Testing and Inspection Locations View 151-6 Page 978 P1180 - P1184: Testing and Inspection P1184 For diagnosis of code P1184 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 2167 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Page 9108 Page 2015 View 151-15 Page 8434 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 7844 Page 7641 Part 3 4. Remove the parts in the order indicated in the illustrations and tables. NOTE: Seat shown disassembled for clarity. Item 2: D-ring Bolt Cover Removal Note 1. Push up to remove the D-ring bolt cover. INSTALLATION 1. To install, reverse the removal procedure. Item 6: Center Safety Belt And Retractor Assembly Bolt(s) Installation Note 1. Make sure the retractor locator tabs are in place before tightening fasteners. Item 2: D-ring Bolt Cover Installation Note 1. Make sure the D-ring and belt move freely before installing. Page 6352 Note: The bussed electrical center is located in the engine compartment. Page 1050 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9403 Test O7-O8 Normal Operation The SJB monitors the headlamp switch position. When the headlamp switch is in the parking lamps ON position, the SJB supplies voltage to the parking and license lamps. If a problem is detected with any of the signal circuits to the headlamp switch, the SJB will default the parking lamps and the headlamps ON. The LH front parking/turn lamp and side marker are supplied voltage from circuit 1340 (DG). The RH front parking/turn lamp and side marker are supplied voltage from circuit 1339 BK/PK). The LH auxiliary parking lamp is supplied voltage from circuit 1344 (VT/LB). The RH signal mirror is supplied voltage from circuit 1343 (PK/OG). The LH rear lamp is supplied voltage from circuit 1364 (DB/YE). The RH rear turn lamp is supplied voltage from circuit 1366 TN/RD). The license lamps are supplied voltage from circuit 1370 (DG/LG). Ground for the LH front and side lamps is supplied through circuit 1205 (BK) from the BEC. Ground for the rear lamps is supplied through circuit 1205 (BK). Possible Causes - circuit 1205 (BK) open - circuit 1339 (BK/PK) open - circuit 1340 (DG) open - circuit 1343 (PK/OG) open - circuit 1344 (VT/LB) open - circuit 1364 (DB/YE) open - circuit 1366 (TN/RD) open - circuit 1370 (DG/LG) open Page 826 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 268 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0203 refer to chart Technician Safety Information Side Air Bag: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Seat side air bag modules with damaged covers must be replaced. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced (cleaning is permissible). - Do not disconnect the wire connector at the seat side air bag module. This is a permanent connection. Doing so may result in accidental air bag deployment, which may result in personal injury. - Inspect the mounting surfaces of the side air bag module and the seat back frame mounting bracket for any foreign objects, before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the side air bag deployment chute and the side air bag cavity in the seat back pad for any foreign objects. If any foreign objects are found remove them. Failure to do so may result in personal injury in the event of an air bag deployment. - Before installing the side air bag module, check it for damage and foreign objects. If the air bag module is damaged, replace it. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Check the side air bag deployment chute and clips for damage. The deployment chute and clips must not be repaired. If there is any damage to the deployment chute or clips, the seat back trim cover and deployment chute must be installed new as a unit. - If the air bag deployment chute is not properly positioned and completely closed, the side air bag may not deploy properly. Page 267 P0200 - P0204: Testing and Inspection P0203 OBD II - Base Gasoline For diagnosis of code P0203 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4463 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 7339 Air Bag Control Module: Diagrams Page 5580 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: Brake Line-To-HCU Fittings Removal Note 1. Brake lines must be re-installed in the same location as removed. Item 4: HCU Removal Note 1. Remove the Anti-Lock Brake System (ABS) module. For additional information, REFER to Anti-Lock Brake System (ABS) Module. Items 1: Brake Line-To-HCU Fittings Installation Note 1. Bleed the brake system. Page 3683 Exhaust Manifold: Service and Repair Exhaust Manifold-RH Exhaust Manifold-RH 1. With the vehicle in neutral, position it on a hoist. 2. Remove the dual converter Y-pipe. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Item 3: Exhaust Manifold Nut Installation Note Page 8572 View 151-17 Brake Booster Sensor View 151-3 Page 1860 Main Relay (Computer/Fuel System): Testing and Inspection Page 75 Inspection Page 169 P0150 - P0154: Testing and Inspection P0152 OBD II - Base Gasoline For diagnosis of code P0152 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code P1436 P1435 - P1439: Testing and Inspection P1436 For diagnosis of code P1436 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6250 Page 4347 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 7088 Page 5696 Brake Pedal Assy: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 2504 Climate Controlled Seat Module, Driver Side View 151-16 Page 6686 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Sliding Door Contact Switch, Right Door Position Switch: Locations Sliding Door Contact Switch, Right View 151-14 Locations View 151-13 Page 6604 View 151-9 Page 6078 Starter Motor: Testing and Inspection COMPONENT TESTS WARNING: When repairing the starter motor or carrying out other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid is "electrically hot" at all times. Failure to follow these instructions can result in personal injury. CAUTION: A protective cap or boot is provided over the battery input terminal on all vehicle lines and must be installed after repairing. Be sure to disconnect the battery ground cable before repairing the starter motor. Connect the 73III Automotive Meter at the component terminal rather than at the wiring end connector. Making a connection at the wiring end connector could result in false readings because the meter will not pick up a high resistance between the wiring connector and the component. Starter Motor - Motor Feed Circuit 1. Make sure the battery is fully charged. Carry out a battery load test. 2. Disconnect the inertia fuel shutoff (IFS) switch. 3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal. 4. Connect the 73III Automotive Meter positive lead to the battery positive (+) post. Connect the negative lead to the M-terminal. 5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.8 volt or less. 6. If the voltage reading is 0.8 volt or less, go to the Starter Motor - Ground Circuit Component Test. 7. If the voltage reading is greater than 0.8 volt, this is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid. Move the 73III Automotive Meter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading at the B-terminal is lower than 0.8 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts. 8. Remove the cables from solenoid B-, S- and M-terminals. Clean the cables and connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop reading is still greater than 0.8 volt when checked at the M-terminal and less than 0.8 volt when checked at the B-terminal, the concern is in the solenoid contacts. Install a new starter motor. 9. If the voltage reading taken at the solenoid B-terminal is still greater than 0.8 volt after cleaning the cables and the connections at the solenoid, the concern is either in the positive (+) battery cable connection or in the positive battery cable itself. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new positive battery cable. Starter Motor - Ground Circuit A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit. Check the voltage drop in the ground circuit as follows: 1. Connect the 73III Automotive Meter positive lead to the starter motor housing (the connection must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery terminal. 2. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The reading should be 0.5 volt or less. 3. If the voltage is more than 0.5 volt, clean the negative cable connections at the battery, the body ground connections, and the starter ground Page 4145 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 9286 View 151-10 Sliding Door Contact Switch, Right Door Position Switch: Diagrams Sliding Door Contact Switch, Right Page 9705 Windshield: Service and Repair WINDSHIELD GLASS Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the cowl panel grille. 2. Remove the interior mirror. 3. Remove the LH and RH windshield side garnish mouldings. 4. If equipped, remove the overhead console. 5. Lower the front portion of the headliner. Page 1627 Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The air conditioning evaporative temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Locations View 151-5 Locations View 151-29 Page 2998 Refrigerant Oil: Fluid Type Specifications PAG Refrigerant Compressor Oil (R-134a Systems) US F7AZ-19589-DA (Motorcraft YN-12-C) .............................................................................................................................................. WSH-M1C231-B Canada F7AZ-19589-DA (Motorcraft CYN-12-C) ........................................................................................................................................... WSH-M1C231-B Page 508 Inspection Page 6092 Service and Repair Door Sensor/Switch (For Alarm): Service and Repair DOOR DISARM SWITCH - DRIVER DOOR REMOVAL 1. Remove the driver door trim panel. 2. Position the watershield aside. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Driver Door Disarm Switch Installation Note 1. The driver door disarm switch mark must be positioned towards the harness side of the switch prior to installation. Page 3852 Page 7917 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Page 6007 Page 7646 Seat Belt: Tools and Equipment D-Ring Installation Kit Special Tool(s) Page 749 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7932 Page 819 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9486 Headlamp Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. Page 6023 Page 7343 Air Bag Control Module: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. Page 7431 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION Page 9380 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT The fuel level input (FLI) is a hard wire signal input to the PCM from the fuel pump (FP) module. Refer to the description of the FLI in the On-Board Diagnostics II Monitors. Page 1079 P1285 - P1289: Testing and Inspection P1289 For diagnosis of code P1289 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Engine - Spark Knock on Light Load/Acceleration Variable Induction Control Actuator: All Technical Service Bulletins Engine - Spark Knock on Light Load/Acceleration TSB 07-16-17 08/20/07 SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION - 3.8L, 3.9L, AND 4.2L - SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC) FORD: 2001-2004 Mustang 1996-2003 Windstar 1997-2003 E-150 1997-2008 F-150 2004-2007 Freestar MERCURY: 2004-2007 Monterey ISSUE Various vehicles equipped with a 3.8L, 3.9L or 4.2L engine and Split Port IMRC may exhibit spark knock under light load and acceleration. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect for disconnected IMRC actuator rods. 1. Check both right hand and left hand side IMRC rods are properly attached to the actuator motor and intake manifold runner. 2. If the IMRC actuator rods are found to be connected properly, do not continue with this TSB. Refer to Powertrain Control/Emission Diagnosis Manual. 3. If any IMRC actuator rods are disconnected, refer to Workshop Manual (WSM), Section 303-14 for IMRC service. 4. If any IMRC actuator rod linkages are found disconnected, replace all four (4) linkage rod retainers. (Figure 1) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071617 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time Page 5075 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 3558 Locations View 151-9 Page 6858 Accumulator HVAC: Service and Repair SUCTION ACCUMULATOR REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Page 6220 Page 9049 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Locations Page 9512 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 Page 6118 Fuse Block: Locations Bussed Electrical Center (BEC) Specifications Drive Belt: Specifications Component Location Service and Repair Air Cleaner Housing: Service and Repair AIR CLEANER ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Air Cleaner Cover Removal Note 1. NOTE: No tools are needed to remove the air cleaner cover. Removal should be carried out using hands only. Release the clamps and separate the air cleaner cover from the air cleaner tray. INSTALLATION 1. To install, reverse the removal procedure. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Harness: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 6111 Page 9348 Symbols Part 3 Page 2934 Page 720 - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0741 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6279 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Page 8783 Power Seat Switch: Testing and Inspection Seat Adjust Switch, Passenger Side Front Page 8487 The perimeter lighting feature requests the headlamps and parking/position lamps to be on when the key is in the OFF position and the customer activates an external unlock feature (remote transmitter, keyless entry keypad, door lock cylinder). The perimeter lighting feature requests the headlamps and park/position lamps to be off when 25 seconds have elapsed since the last external unlock activation, or the customer activates an external lock feature (remote transmitter, keyless entry keypad), or the key is cycled to a position other than OFF. Page 1275 NOTE 16: REFER to Exterior Lighting component testing in Lighting and Horns for further diagnosis of the Smart Junction Box (SJB). Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Lighting and Horns NOTE 17: REFER to Antilock Brakes / Traction Control Systems, for further diagnosis of the cause of the incorrect brake pedal status from the ABS to the PCM. Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Gasoline Fuel System Fuel Pressure Sensor/Switch: Description and Operation Gasoline Fuel System FUEL RAIL PRESSURE SENSOR Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 36) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 37) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve 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. Page 7268 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 5081 Disclaimer Page 8858 Item 2: Speed Control Cable Installation Note 1. NOTE: Incorrect wrapping of the speed control cable core wire around the speed control actuator pulley may result in a high idle condition. Insert the speed control cable slug into the speed control actuator pulley slot. 1 Gently push the retaining spring. 2 Insert the speed control cable slug completely into the speed control actuator pulley slot. 2. NOTE: Make sure the rubber seal is correctly seated onto the speed control cable cap. Align the speed control cable cap tabs with the slots in the speed control actuator housing and seat the speed control cable cap. 3. Rotate the speed control cable cap clockwise until the locking tab engages. P0755 P0755 - P0759: Testing and Inspection P0755 Torqshift For diagnosis of code P0755 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Page 2821 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 5427 Material Material 1. With the vehicle in neutral, position it on a hoist. 2. Remove the transaxle. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: Item 3: Crankshaft Rear Seal Removal Note 1. Using the special tools, remove the crankshaft rear seal. Page 3918 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 5326 9. Install the rear transaxle support insulator bracket. 10. Position the transaxle support insulator in place and loosely install the bolt and nut. 11. Tighten the retaining bolt and nut. 12. Install the upper main control cover bolts. Adjustable Pedal Motor View 151-11 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 1974 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 7855 9. NOTE: - The repair coating will air-dry in approximately 1 minute and can be energized within 3 minutes. - Optimum adhesion occurs after approximately 24 hours. After optimum hardness is achieved, clean the repaired area with a non-alcohol based window cleaner. Page 9389 Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System INERTIA FUEL SHUTOFF (IFS) SWITCH Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 76) 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 a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Page 7078 Part 1 Page 2010 View 151-21 Page 7215 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Center Instrument Panel Finish Panel Removal Note 1. Remove the center instrument panel finish panel. INSTALLATION 1. To install, reverse the removal procedure. Page 6156 Page 6364 Page 5022 Series 5 Four Tower Coil Pack Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six tower models. Two adjacent coil towers share a common coil and are called a matched pair. For six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4 (Figure 61) and (Figure 62). For four-tower coil pack (four cylinder) applications the matched pairs are 1 and 4, and 2 and 3 (Figure 63) and (Figure 64). 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. ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 7766 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Second Row, LH SIDE IMPACT SENSOR - SECOND ROW, LH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Page 6727 1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B. 2. Fold loose leather out of the way. 3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke. 4. Fold the leather back into its original position. 5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to the wheel spoke (apply pressure for at least 30 seconds). NOTE THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE REPAIR AREA. 6. Reinstall steering wheel. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070403 Use SLIS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time. DEALER CODING CONDITION BASIC PART NO. CODE 3600 33 Disclaimer Page 5042 Page 9568 Page 6130 Page 4233 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) P0451 P0450 - P0454: Testing and Inspection P0451 For diagnosis of code P0451 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4063 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 2961 6. If fluid contamination or transaxle failure is confirmed by the sediment in the bottom of the fluid pan, the transaxle must be disassembled and completely cleaned. This includes the torque converter, cooler bypass valve, coolers and cooler lines. 7. Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Material 1. With the engine running, check the transmission fluid level and condition. If the fluid level and fluid condition is not within specification, adjust to correct level. For additional information, refer to Preliminary Inspection. See: Powertrain Management/Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Initial Inspection/Preliminary Inspection 2. Turn the engine OFF. 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Remove the lower retaining clip from the lower transaxle cooler line fitting. 5. Depress the tabs on the plastic insert retainer and remove cooler line from fitting. 6. Attach a flexible hose, approximately 0.9 mm (3.0 ft.) in length, to the fluid cooler tube with the other end in a suitable, 15-quart container. Page 4611 1. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. NOTE: If the fuel tube or retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retainer clip legs. Once the retainer clip legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Disconnect the fuel tube quick release coupling. Push the connector towards the tube to release pressure. - Press the fuel tube quick release coupling button and pull the fuel tube to disconnect. INSTALLATION 1. To install, reverse the removal procedure. 2. Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test 3. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission Repair Verification Drive Cycle Item 3: Vapor Tube Quick-Connect Fittings Installation Note 1. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure the tube is fully seated, pull on the tube. NOTE: Apply clean engine oil to the end of the tube before inserting a tube into the connector. Install the fuel tube quick-release coupling. Page 154 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 550 P0500 - P0504: Testing and Inspection P0501 For diagnosis of code P0501 refer to chart P0463-P0503 NOTE 6: Go to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection NOTE 8: Vehicle speed information is provided by the anti-lock brake system. Go to Antilock Brakes / Traction Control Systems. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection Page 4951 2. Position the rubber plunger rearward and remove the cable from the accelerator pedal. INSTALLATION 1. To install, reverse the removal procedure. Page 221 P0180 - P0184: Testing and Inspection P0182 OBD II - Base Gasoline For diagnosis of code P0182 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9694 1. CAUTION: Care must be taken to avoid scratching the pinch weld. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld. 2. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary. 3. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. NOTE: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area Apply urethane glass prep twice around the glass surface to be prepped in the area indicated by the squares marked on the glass. 5. CAUTION: Apply using deliberate strokes, making sure not to overlap the applied area. Cut the urethane glass primer to the same area that was prepped in the previous step. Allow five minutes to dry. 6. Cut the urethane adhesive applicator tip to specification. 7. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, urethane adhesive must be used due to its one-hour cure time. Page 8181 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 779 P0770 - P0774: Testing and Inspection P0772 For diagnosis of code P0772 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8313 1. CAUTION: Care must be taken to avoid scratching the pinch weld. Trim the remaining urethane on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld. 2. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary. 3. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. NOTE: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area Apply urethane glass prep twice around the glass surface to be prepped in the area indicated by the squares marked on the glass. 5. CAUTION: Apply using deliberate strokes, making sure not to overlap the applied area. Cut the urethane glass primer to the same area that was prepped in the previous step. Allow five minutes to dry. 6. Cut the urethane adhesive applicator tip to specification. 7. CAUTION: If the vehicle is to be driven within 24 hours of urethane adhesive application, urethane adhesive must be used due to its one-hour cure time. P2131 P2130 - P2134: Testing and Inspection P2131 For diagnosis of code P2131 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3109 Locations View 151-9 Page 1837 Main Relay (Computer/Fuel System): Testing and Inspection Page 8686 Page 9046 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 7461 Attach the seat cushion trim cover J-clips to the seat cushion pan. Item 12: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 15: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 16: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Page 3442 2. Rotate the crankshaft until the timing marks and keyways align. 3. Compress and install a retaining pin to hold the timing chain tensioner. 4. Remove the camshaft gear, crankshaft gear and the timing chain as an assembly. 5. Remove the bolts and the timing chain tensioner. Items 23-17: Timing Components Installation Note Page 3199 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Page 8672 Symbols Part 4 Page 6221 Service Precautions Air Bag Deactivation Indicator: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Page 2238 Solar Sensor: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Solar Radiation Sensor The solar radiation sensor supplies information to the EATC module indicating sunload. Page 552 P0500 - P0504: Testing and Inspection P0503 For diagnosis of code P0503 refer to chart P0463-P0503 NOTE 6: Go to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Seat Adjust Switch, Passenger Side Front Page 9317 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 8711 View 151-15 Page 8779 Page 5020 Ignition Coil: Description and Operation Coil Pack COIL PACK Horizontal Connector Six Tower Coil Pack Series 5 Six Tower Coil Pack Page 6372 Page 1433 P2100 - P2104: Testing and Inspection P2104 For diagnosis of code P2104 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9401 Test O3-O5 Front Heater Core: Service and Repair Front HEATER CORE - FRONT REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Clamp off and disconnect the heater hoses from the heater core. 2. Lower the glove compartment. ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 5328 16. Install the oil filler cap. 17. Install the hood latch. 18. Connect the electrical connectors. 1 Connect the digital Transmission Range (TR) sensor electrical connector. 2 Connect the transaxle electrical connector. 3 Connect the speed control electrical connector. 19. Install the wiper arm and pivot assembly. 20. Install the air cleaner assembly. Specifications Brake Fluid: Specifications Brake Fluid Type High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 Page 2168 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Engine Cooling Fan Relay 1 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 1 Page 6998 INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Page 7064 Special Tool(s) Page 9423 Specifications Piston Ring: Specifications Piston ring end gap-compression (top, in gauge) ............................................................................................................................................. 0.17-0.33 mm Piston ring end gap-compression (bottom, in gauge) ......................................................................................................................................... 0.3-0.55 mm Piston ring end gap-oil ring (steel rail, in gauge) ............................................................................................................ 0.15-0.65 mm (0.006-0.026 inch) Piston ring groove width-compression (top) ............................................................................................................... 1.535-1.52 mm (0.0603-0.0598 inch) Piston ring groove width-compression (bottom) Piston ring groove width-oil .................................................................................................................................... 3.05-3.03 mm (0.12001-0.11929 inch) Piston ring width-compression (top and bottom) .................................................................................................. 1.460-1.490 mm (0.05748-0.05866 inch) Piston ring width-oil ring .............................................................................................................. ............................................................. Side seal, snug fit Piston ring-to-groove clearance-1st ring ............................................................................................................... 0.030-0.065 mm (0.0012-0.00315 inch) Piston ring-to-groove clearance-2nd ring ................................................................................................................ 0.030-0.070 mm (0.0012-0.0028 inch) Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 6978 Compressor Shaft Seal: Service and Repair AIR CONDITIONING (A/C) COMPRESSOR SHAFT SEAL Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. Locations Starter Motor: Locations View 151-5 Page 4959 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. System Diagnosis P0870 - P0874: Testing and Inspection For diagnosis of code P0871 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 3443 1. Install the timing chain tensioner and bolts. 2. If necessary, retract the tensioner pad retracting mechanism and insert a retaining pin. 3. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position. 4. Turn the camshaft gear so that the timing mark is on the bottom of the balance shaft. Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 1366 Inspection Page 1646 Page 7360 3. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 1: Instrument Panel Center Trim Panel Removal Note 1. Pull out to release the retaining clips. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 1286 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2383 Accessories - Trailer Tow Harness Kit Service Tip Trailer Adapter Kit: Technical Service Bulletins Accessories - Trailer Tow Harness Kit Service Tip Article No. 03-24-2 12/08/03 ELECTRICAL - TRAILER TOW SERVICE KIT - SERVICE TIP FORD: 1999-2003 WINDSTAR 2004 FREESTAR MERCURY: 2004 MONTEREY ISSUE For the 1999-2003 Windstar and 2004 Freestar/Monterey vehicles, due to changes in vehicle wiring, trailer tow wiring harnesses must be ordered based on the vehicle build date. Should a vehicle exhibit a trailer tow wiring concern, rather than diagnosing and/or repairing, order and install a replacement harness service kit. If a customer wishes to have trailer tow wiring installed on their vehicle, order the proper wiring kit. Do not attempt to install and modify trailer tow wiring that is not specified for the vehicle. This will lead to unnecessary work and possible failures. ACTION The correct service kit must be ordered according to the vehicle build date, as outlined in this TSB. Refer to the part information chart for application and correct service kit. SERVICE TIP WIRING CHANGES April of 2002: The connector from the trailer tow/reverse park aid harness (15k867) to the main body harness was changed to a water sealed connector. December of 2002: The circuits for the electric trailer brake were eliminated resulting in a change to the water sealed connector. Provisions for an electric brake are in all service kits. Circuitry for electric brakes are not present in vehicles built after 12/02/2002. 2004 Model Year: Dealer installed trailer tow kits will include a harness, three relays and two fuses. The relays and fuses are to be installed in the under hood fuse box bussed electrical center (BEC). The harness mates with a connector on the underside of the vehicle rearward of the spare tire. Replacing harnesses and removing interior trim is no longer required. Circuitry for electric trailer brakes are not included in the vehicle. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Locations View 151-16 Page 4866 Page 7324 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Spring Lock Coupling Coupler HVAC: Service and Repair Spring Lock Coupling SPRING LOCK COUPLING Remover, Refrigerant Coupling Spring SPECIAL TOOL(S) DISCONNECT 1. Remove the spring lock coupling clip, if equipped. 2. CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. Push the tool into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool. 3. CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. Remove the spring lock coupling spring with a small hooked wire. CLEANING Page 4934 Page 3430 - Tighten the engine front cover studs to 7 Nm (62 inch lbs.). - Using a new gasket, install the coolant pump. - Tighten the fasteners in the sequence shown. Tighten bolt No. 12 to 10 Nm (89 inch lbs.). - Tighten all other fasteners to 28 Nm (21 ft. lbs.). 5. Install the two oil pan bolts and tighten to 10 Nm (89 inch lbs.). 6. Install the catalyst monitor sensor electrical connector bracket. 7. Connect the catalyst monitor sensor electrical connector. Item 9: Crankshaft Front Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation. Assemble the special tools, then place the crankshaft front seal onto the special tools. Page 3915 Page 926 P1125 - P1129: Testing and Inspection P1127 For diagnosis of code P1127 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Description and Operation Seat Belt Extension: Description and Operation SAFETY BELT EXTENSION ASSEMBLY In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 inches) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through the dealership parts department at no cost. Safety belt extensions are only available with black webbing. There is one extension assembly available for the front and rear seating positions. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use the extension to change the fit of the shoulder belt across the torso. Page 7799 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 1577 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Passenger Side Page 8192 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 7004 Condenser HVAC: Service and Repair CONDENSER CORE REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. Page 833 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0963 refer to chart Page 7569 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 728 P0740 - P0744: Testing and Inspection P0744 For diagnosis of code P0744 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 521 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P0457 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1405 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9670 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7274 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 7259 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Service and Repair Lateral Accelerometer: Service and Repair Accelerometer Removal and Installation NOTE: When installing a new accelerometer, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. 1. Remove the driver side front seat. 2. Remove the lower B-pillar trim panel. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: Electrical Connector Removal Note 1. Fold back the carpeting flap to gain access to the accelerometer. Page 7331 Page 963 Inspection Locations P030x P0300 - P0304: Testing and Inspection P030x For diagnosis of code P030x refer to chart P0230-P0360 NOTE: "x" equals any number 0 through 9 or letter A through F. If there is no link in the chart then: Page 3769 Page 2484 View 151-5 Page 2674 Page 204 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0174 refer to chart Page 700 Inspection 4R100 For diagnosis of code P0731 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 6514 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Page 6280 Page 2334 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8380 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 7444 Page 130 Inspection Page 5126 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Description and Operation Fuel Level Sensor: Description and Operation FUEL LEVEL INPUT The fuel level input (FLI) is a hard wire signal input to the PCM from the fuel pump (FP) module. Refer to the description of the FLI in the On-Board Diagnostics II Monitors. Auxiliary Climate Control Housing, Assembly and Components Evaporator Case: Service and Repair Auxiliary Climate Control Housing, Assembly and Components AUXILIARY CLIMATE CONTROL HOUSING, ASSEMBLY AND COMPONENTS REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Lubricate the coolant hoses with plain water only if needed. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Remove the LH quarter trim panel. 4. Clamp off the heater hoses at the front of the underbody auxiliary heater outlet and inlet lines. 5. Disconnect the auxiliary lines. 1 Disconnect the auxiliary A/C fittings. 2 Disconnect the auxiliary heater hoses. Page 2828 Spark Plug: Service and Repair IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. If removing the ignition coil, remove the wiper motor and pivot assembly. Page 8264 To remove individual parts, only carry out the listed steps. INSTALLATION 1. To install, reverse the removal procedure. Page 3771 Page 9776 Wiper Switch: Testing and Inspection Page 6351 Page 24 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagrams Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................... 11.6 Liters (12.25 quarts) Diagrams Brakes - Rear Caliper Leaks (Mexico Vehicles Only) Brake Caliper: Customer Interest Brakes - Rear Caliper Leaks (Mexico Vehicles Only) TSB 06-14-11 07/24/06 REAR BRAKE CALIPER LEAKS (VEHICLES SOLD IN MEXICO ONLY) - SERVICE TIP FORD: 2004-2006 Freestar MERCURY: 2004-2006 Monterey ISSUE 2004-2006 Freestar / Monterey vehicles may exhibit rear brake caliper fluid leaks - Service Tip. ACTION The rear brake caliper fluid leaks could be fluid seepage that may occur under certain conditions. Wetness around the piston seal is acceptable and should merely be wiped clean without any required repairs. SERVICE PROCEDURE If fluid accumulates enough that it causes dripping, then replace the brake caliper with the part that has been recently updated in service. Refer to Workshop Manual, Section 206-04, Rear Disc Brake. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 1109 07 Disclaimer Page 9539 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 6182 Page 2151 Page 1929 Page 2055 Page 7305 Page 1982 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Page 1902 Page 5874 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder-Bypass Condition Test 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a new brake master cylinder must be installed. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon application or release of the brake pedal is normal and shows that the compensating ports are not plugged. Page 829 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift For diagnosis of code P0962 refer to chart Page 2574 Impact Sensor: Vehicle Damage Warnings CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. Page 811 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4315 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The heated oxygen sensor (HO2S) (Figure 38) 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 temperatures of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will turn on the heater by providing the ground when the proper conditions occur. Since model year 1998 a high power HO2S heater and heater control system have been installed on the Stream 1 HO2S sensors of most vehicles. The high power heater reaches closed loop fuel control temperatures faster, which allows closed loop engine operation sooner. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Locations View 151-10 Page 7539 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 6957 Compressor Clutch: Description and Operation A/C COMPRESSOR AND CLUTCH ASSEMBLY NOTE: Internal A/C compressor components are not repaired separately. The Visteon FS-10 A/C compressor is repaired only as an assembly. The A/C clutch disc and hub assembly, A/C clutch pulley, A/C clutch field coil and the compressor shaft seal are repairable. - Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The Visteon FS-10 A/C compressor has the following characteristics: A ten-cylinder swashplate design utilizing the tangential design mount. - A one-piece lip-type seal (installed from the front of the A/C compressor) is used to seal it at the shaft opening in the assembly. - Five double-acting pistons operate within the cylinder assembly. The pistons are actuated by a swashplate that changes the rotating action of the shaft to a reciprocating force. - Reed-type discharge valves are located between the cylinder assembly and the head at each end of the A/C compressor. - The A/C compressor uses PAG oil or equivalent. This oil contains special additives required for the A/C compressor. - The A/C compressor oil from vehicles equipped with an FS-10 A/C compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this A/C compressor because carbon from the piston rings will discolor the oil. A/C Compressor Clutch Assembly The magnetic A/C clutch disc and hub assembly has the following characteristics: The A/C clutch drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. - The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly move the clutch plate away from the A/C clutch pulley. Page 9214 Test G2-G3 Power Window Motor, Left Front View 151-18 Page 4655 Page 7937 Page 5343 Item 1: Front Axle Wheel Hub Retainer Installation Note 1. CAUTION: Install and tighten the new axle wheel hub retainer to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the retainer and lead to bearing failure. Always install a new retainer after loosening the retainer or when the retainer has not been installed to specification in a continuous rotation. CAUTION: Never use power tools to tighten the axle wheel hub retainer. NOTE: Apply a small patch of sealant to the last five outboard CV joint threads. Install a new axle wheel hub retainer. ^ Remove the steel rod from the brake disc. Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 7116 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Disconnect the front auxiliary outlet and inlet line fittings. 1 Disconnect the fittings. 2 Remove the nuts and the line bracket. Discard the O-ring seals. 4. Remove the three bolts and position the shield aside. 5. Disconnect the fittings at the front tube-in-tube fitting. - Discard the O-ring seals. Page 2681 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 1421 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4138 View 151-13 Page 7012 Control Assembly: Description and Operation Control Components ELECTRONIC MANUAL TEMPERATURE CONTROL Climate Control Assembly (EMTC Module) The climate control assembly integrates the temperature control, airflow mode selection, A/C request button, recirculated air request button and rear defog switch into a single unit. The temperature control switch setting determines air temperature. Movement of the temperature display from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door(s) and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the climate control assembly and cannot be separately replaced. The A/C request switch determines A/C compressor operation, except when the function selected is OFF, MAX or DEFROST. The A/C request switch is an integral part of the climate control assembly and cannot be separately replaced. The recirculated air request button can select recirculated air in any mode except DEFROST and fresh air in any mode except MAX A/C and OFF. The rear defog button signals activation of the heated backlight. The rear defog button is an integral part of the climate control assembly and cannot be installed separately. The EMTC module is not equipped with self-test capabilities. Heated Oxygen Sensor (HO2S) #22 Page 6315 Page 7140 1. Connect an R-134a service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 2. Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 3. Turn off the vacuum pump. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves. 2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum pump. 3. Open all valves on the R-134a manifold gauge set and both service gauge port valves. 4. Turn on the vacuum pump and evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. 5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port valves) and turn off the vacuum pump. 6. Observe the low-pressure gauge for five minutes to make sure that the system vacuum is held. If vacuum is not held for five minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Charging Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Connect an R-134a A/C service center to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer. Refrigerant System Charging NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. 1. Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Assemble the R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following the automatic refrigerant charging meter operating instructions. 3. Charge the refrigerant system following the automatic refrigerant charging meter operating instructions. 4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select A/C operation and allow the refrigerant charge to complete. Page 76 P0105 - P0109: Testing and Inspection P0108 OBD II - Base Gasoline For diagnosis of code P0108 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: Page 8153 Symbols Part 2 Page 2990 Refrigerant: Service and Repair Handling of Contaminated Refrigerants HANDLING OF CONTAMINATED REFRIGERANTS CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. NOTE: A new suction accumulator or receiver/drier must be installed as directed by the air conditioning 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 your area with the correct equipment to carry out this service. 2. Determine and correct the cause of the customers initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Page 9062 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. System Diagnosis P1440 - P1444: Testing and Inspection For diagnosis of code P1443 refer to the system experiencing the problem. Computers and Control Systems P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1045 P1270 - P1274: Testing and Inspection P1271 OBD II - Base Gasoline For diagnosis of code P1271 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 511 P0450 - P0454: Testing and Inspection P0453 For diagnosis of code P0453 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9254 View 151-19 Page 6884 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 3344 Oil Pressure Sender: Service and Repair CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the generator. 2. Remove the accessory drive belt idler pulley. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Items 3-5: Generator Mounting Bracket Removal Note 1. NOTE: Clearance between the engine and vehicle frame is limited. The A/C compressor mounting bracket brace, two long bolts, and generator mounting bracket should be removed from the engine as an assembly. Page 9183 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 8755 P2257 P2255 - P2259: Testing and Inspection P2257 For diagnosis of code P2257 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Page 3832 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 2711 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 5160 A/T - 4F50N No 1-2 Upshift/DTC P0732 Set Clutch: Customer Interest A/T - 4F50N No 1-2 Upshift/DTC P0732 Set TSB 04-17-10 09/06/04 4F50N TRANSAXLE NO 1-2 UPSHIFT AND DTC P0732 FORD: 2004-2005 Taurus, Freestar MERCURY: 2004-2005 Sable, Monterey This article supersedes TSB 04-15-12 to update the vehicle model years. ISSUE Some 2004-2005 Taurus/Sable and Freestar/Monterey vehicles, may exhibit a diagnostic trouble code (DTC) P0732 and a no 1-2 upshift condition. This may be due to an intermediate clutch piston seal becoming torn or loose (de-bonded) from the piston. ACTION To service, perform normal diagnosis per Workshop Manual. If the cause is determined to be internal to the transaxle, inspect the intermediate clutch piston seal. The outer clutch seal is bonded to the piston. If the seal is torn or loose replace the piston. Inspect the intermediate clutch plates and replace if necessary. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7E005 D8 Disclaimer Page 3349 1. NOTE: If the oil pan is not installed within four minutes, remove the sealer and reapply. Clean and apply sealant to the oil pan sealing areas shown and install the oil pan rear seal. 1. Apply silicone gasket and sealer to the rear main bearing cap. 2. Install the rear oil pan seal. 3. Apply a bead of silicone gasket and sealer to the oil pan mating surface. Oil Pan Torque Sequence 2. Install the oil pan and start the bolts. - Tighten the oil pan bolts in the order shown. Page 3866 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4544 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 2861 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 3899 Oxygen Sensor: Harness Locations View 151-6 Page 9181 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. System Diagnosis P2015 - P2019: Testing and Inspection For diagnosis of code P2019 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1949 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Service Precautions Throttle Body: Service Precautions CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body can occur. Page 8610 Power Seat Motor: Diagrams Power Seat Motor Assembly, Left Page 8989 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 916 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4011 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 1034 P1265 - P1269: Testing and Inspection P1267 OBD II - Base Gasoline For diagnosis of code P1267 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9753 Windshield Washer Reservoir: Service and Repair WINDSHIELD WASHER PUMP AND RESERVOIR REMOVAL 1. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. CAUTION: Do not make any electrical connections prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Disconnect the battery. 2. Remove the RF front wheel. 3. Position the RF splash shield aside. Page 5579 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the battery tray. 2. Raise and support the vehicle. Page 3089 Page 7074 Heater Core: Testing and Inspection HEATER CORE WARNING: Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. 1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require the installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. CARRY OUT a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater hose to heater core attachments. A coolant leak in the heater hose could follow the heater core tube to the heater core and appear as a leak in the heater core. 2. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specified clamps can cause leakage at the heater hose connection and damage the heater core. Check the integrity of the heater hose clamps. Heater Core - Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hoses to see if they are hot. 4. If the outlet only is not hot: - the heater core may have an air pocket. - the heater core may be plugged. 5. If the inlet only is not hot: - the thermostat may not be working correctly. Heater Core - Pressure Test Use the Pressure Test Kit to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core. 3. Install a short piece of heater hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater hoses with water and install the two plugs BT-7422-B and the adapter BT-7422-A from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Pressure Test Kit to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test. Heater Core - Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. 3. Connect the 101 mm (4 inch) test heater hoses with plug and adapter to the core tubes. Then connect the Pressure Test Kit to the adapter. Page 4923 Inertia Fuel Shutoff Switch: Service Precautions WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. General Procedures Keyless Entry Key-Pad: Service and Repair General Procedures KEYLESS ENTRY KEYPAD CODE PROGRAMMING 1. Enter the permanent factory keyless entry keypad code. 2. Press the 1/2 button within 5 seconds to activate the programming mode. Holding the 1/2 button for more than 2 seconds after activation will erase the stored customer code. The door locks lock, then unlock, confirming the code is erased. 3. Within 5 seconds, enter the new 5-digit keyless entry keypad code. The door locks lock and unlock to confirm the new code is programmed. Page 1272 - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1702 refer to chart If there is no link in the chart then: Page 8440 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. P0135 P0135 - P0139: Testing and Inspection P0135 For diagnosis of code P0135 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1910 Page 9328 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 9325 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 Page 8684 Page 2790 Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Page 6394 Page 570 Inspection Page 3299 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Items 1-3: Rocker Arm Removal Note 1. If the rocker arms are to be reused, they must be installed in their original location. Mark the rocker arms for location before removing. 2. If removing valve springs, rotate the crankshaft until the piston is at the top of its stroke with both the intake and exhaust valves closed prior to removing the rocker arm. Item 7: Valve Tappet Removal Note Page 541 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 438 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3246 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. A related DTC will also be set when this fault 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 cam 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 two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinders and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which will fit only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door handle. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2160 Page 1169 Inspection Page 7390 8. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 9. Through the steering wheel access door, connect the driver air bag module electrical connector. - Close the steering wheel access door. 10. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 11. Connect the battery ground cable. 12. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Item 1: Clockspring Installation Note 1. CAUTION: Make sure the road wheels are in the straight-ahead position and the clockspring is centered before installing the clockspring. NOTE: Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column. Align the clockspring to the steering column and slide it down into place. Make sure the three clockspring retainers are securely snapped in place on steering column. Item 2: Connector Installation Note Page 1631 Page 5543 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Output Shaft Speed Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed Sensor OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (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 generated. Page 5171 ^ Windstar Freestar and Monterey (Figure 3, 4, and 5) Taurus and Sable with column shifter (Figure 6) Page 102 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0118 refer to the Base Gasoline Diagnostic Chart: P0112-P0147 Page 4158 Page 6561 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Page 4107 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Locations View 151-9 Page 8513 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH REMOVAL 1. Remove the door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6677 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Page 6284 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Description and Operation Front Subframe: Description and Operation FRONT SUBFRAME The front subframe is bolted to the body and is used to: aid in structural support. - provide mounting surfaces for the front suspension. - provide mounting points for the front stabilizer bar. - provide mounting for the engine. - provide mounting for the steering gear. - protect the transmission and oil pan from damage. Testing and Inspection Mini ISO Relay: Testing and Inspection Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 988 Inspection Page 3029 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. Page 3000 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) SPECIAL TOOL(S) Refrigerant Oil Adding CAUTION: 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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Part 1 Page 4394 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 6666 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 8878 Page 7430 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Second Row, LH SIDE IMPACT SENSOR - SECOND ROW, LH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Page 5878 1. Disconnect the speed control and the accelerator cables. 2. Remove the wiring harness retaining bracket. 3. Remove the cable bracket bolts and position bracket aside. 4. Remove the bolts and position the speed control module aside. Item 17: Brake Reservoir Cap Removal Note 1. If removing the brake fluid reservoir, use a suitable suction device to drain the reservoir before removal. Page 9527 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 7062 Expansion Block/Orifice Tube: Service and Repair EVAPORATOR CORE ORIFICE Special Tool(s) SPECIAL TOOL(S) REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Remove the RH front wheel. 2. Remove the parts in the order indicated in the illustration and table. Item 2: Evaporator Core Orifice Removal Note 1. Inspect the evaporator core orifice for damage before attempting to remove it from the line. Output Shaft Speed (OSS) Sensor Page 5474 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 716 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and P2070 P2070 - P2074: Testing and Inspection P2070 For diagnosis of code P2070 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 835 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7566 Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts Stage 1 ................................................................................................................................................ .................................................. 25 Nm (18 ft. lbs.) Stage 2 ................................................................ .................................................................................................................................. 45 Nm (33 ft. lbs.) Stage 3 ........................................................................................................................................ ................................ Tighten an additional 105 degrees. Connecting rod-to-pin clearance ...................................................................................................................................... Press fit 8 kilonewtons (1,800 lb) Connecting rod pin bore diameter ....................................................................................................................... 22.94-22.98 mm (0.90315-0.90472 inch) Connecting rod length (center-to-center) ........................................................................................................ 154.66-154.74 mm (6.08896-6.09211 inch) Connecting rod maximum allowable bend ..................................................................................................................... 0.04 per 25 mm (0.0016 per inch) Connecting rod maximum allowable twist ...................................................................................................................... 0.059 per 25 mm (0.002 per inch) Connecting rod side clearance (assembled to crank)-standard .................................................................................... 0.11-0.49 mm (0.0047-0.01929 inch) Connecting rod side clearance (assembled to crank)-service limit ............................................................................................ 0.49 mm (0.0193 inch) max. ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 8700 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Driver Side Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 2223 Cabin Temperature Sensor / Switch: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL In-Vehicle Temperature Sensor The in-vehicle temperature sensor operates in the following manner: - A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger compartment. - An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. - The aspirator hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor. - The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor. Page 280 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0206 refer to chart Locations Page 6670 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 7759 Impact Sensor: Vehicle Damage Warnings CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. Locations View 151-29 Page 8545 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) REMOVAL 1. CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery. 2. Remove the driver seat. 3. Remove the parts in the order indicated in the illustration and table. Description and Operation Seat Belt Buckle: Description and Operation SAFETY BELT BUCKLE PRETENSIONERS As part of the supplemental restraint system (SRS), the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners rotate to remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a frontal impact event exceeding a programmed limit. Page 2533 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 9358 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. P1235 P1235 - P1239: Testing and Inspection P1235 For diagnosis of code P1235 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9733 Locations View 151-6 Page 1743 Page 8921 Special Tool(s) Page 9554 Test W4-W6 P0265 P0265 - P0269: Testing and Inspection P0265 For diagnosis of code P0265 refer to chart B1219-B1317 / P0182-P1272 Page 3115 Page 8881 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Page 3118 Page 5035 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 9215 Test G3-G5 Normal Operation The SJB monitors voltage input from the stoplamp switch. When the SJB senses brake pedal application, the SJB sends voltage to the rear lamps. Voltage for the LH and RH rear lamps is supplied through circuits 1363 (WH/RD) and 1365 (GY/LB) respectively. Voltage for the high mounted stoplamp is supplied through circuit 1456 (RD/LB). Ground for the stoplamps is provided through circuit 1205 (BK). Possible Causes - circuit 1205 (BK) open - circuit 1363 (WH/RD) open - circuit 1365 (GY/LB) open - circuit 1456 (RD/LB) open Page 3965 View 151-5 Page 5266 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Steering Column Opening Cover Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 4136 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 1703 Page 5659 Page 101 P0115 - P0119: Testing and Inspection P0118 OBD II - Base Gasoline For diagnosis of code P0118 refer to chart P0112-P0147 If there is no link in the chart then: Page 5318 Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive shift strategy. Remove the battery tray. 3. Loosen the clamps and remove the air cleaner tube. 4. Remove the air cleaner assembly. 5. Disconnect the electrical connectors. 1 Disconnect the digital Transmission Range (TR) sensor electrical connector. 2 Disconnect the transaxle electrical connector. 3 Disconnect the speed control electrical connector. 6. Remove the wiper arm and pivot assembly. Page 1285 P1705 - P1709: Testing and Inspection Torqshift For diagnosis of code P1705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 6571 located in the instrument cluster. The LTW system must be reset when tire replacement, maintenance, system repair is performed or any time tire pressure is adjusted. To reset the system, press and hold the "Tire Reset" switch for a minimum of three seconds. The LTW warning lamp will flash 3 times, indicating a reset has been initiated. If the lamp illuminates, reset the tire pressure to specification before resetting the system. If the problem persists go to the Symptom Chart. The LTW system is not capable of detecting rapid loss of inflation. The system may not detect loss of inflation in more than one tire. The LTW system can be deactivated. Page 2366 View 151-13 Specifications Wheel Fastener: Specifications Wheel nut fastener .............................................................................................................................. ................................................... 135 Nm (100 ft.lbs.) Page 531 P0460 - P0464: Testing and Inspection P0462 For diagnosis of code P0462 refer to chart P0400-P0462 NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5399 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tires are off of the ground. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the wheel and tire assembly. Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire from the front wheel bearings. If movement exists, a new hub and bearing assembly must be installed. Locations View 151-16 Page 6039 Battery: Description and Operation BATTERY The battery is a 12-volt direct current source connected in a negative ground system. The battery case is sealed with two vent holes to release gases. The battery has three major functions: - engine cranking power source - voltage stabilizer for the electrical system - temporary power when electrical loads exceed the generator output current Brakes - Accelerated rear Brake Pad Wear Brake Rotor/Disc: Customer Interest Brakes - Accelerated rear Brake Pad Wear TSB 04-26-10 12/31/04 REAR BRAKE LINING ACCELERATED WEAR FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit accelerated rear brake pad lining wear, heavily scored rear rotors, or metal pickup in the rear lining. ACTION Replace the rear brake pad linings, machine the rotors as required. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042610A 2004-2005 0.7 Hr. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads Only 042610B 2004-2005 1.6 Hrs. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads, Machine Both Rear Brake Rotors On Vehicle DEALER CODING CONDITION BASIC PART NO. CODE 2200 42 Disclaimer Page 6553 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Page 9502 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 7886 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Diagrams Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Electrical - ABS/TCS/Park Brake Lamps Flickering Traction Control Indicator Lamp: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 4722 1. Remove the accelerator cable from the rubber plunger. 2. Position the plunger rearward and remove the cable from the accelerator pedal. Item 2: Accelerator Pedal Retaining Pin Removal Note 1. Depress the tabs on the accelerator pedal retaining pin and remove the pin. INSTALLATION 1. To install, reverse the removal procedure. Page 6369 Page 6038 Battery: Vehicle Damage Warnings CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A. Page 6633 Part 2 Of 3 Page 7309 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 782 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3617 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater hose away from the heater core tube. 5. Spread the retainer tabs apart and slide the retainer off the tube. - Discard the retainer. CONNECT 1. Clean the tubes and lubricate with coolant hose lubricant or plain water. 2. Install a new coupling retainer into the heater hose coupling housing. 3. Push the heater hose coupling onto the tube. 4. Make sure the heater hose coupling is fully engaged by lightly pulling on the heater hose. Page 1549 Page 3075 Page 8194 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 2020 View 151-21 Page 8165 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 5688 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Manual Transmission P0720 - P0724: Testing and Inspection Manual Transmission P0720 For diagnosis of code P0720 refer to pinpoint test TJ1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests TJ: Output Shaft Speed (OSS) Sensor If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0721 For diagnosis of code P0721 refer to pinpoint test TJ1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests TJ: Output Shaft Speed (OSS) Sensor If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0722 For diagnosis of code P0722 refer to pinpoint test TJ1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests TJ: Output Shaft Speed (OSS) Sensor If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0723 For diagnosis of code P0723 refer to pinpoint test TJ1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/Tests TJ: Output Shaft Speed (OSS) Sensor If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1343 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: Liftgate Ajar Switch Page 4677 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 6151 Page 1742 Relay Box: Diagrams Smart Junction Box (SJB) Page 2095 Page 756 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8379 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 4179 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 Page 4182 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 7454 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Item 17: Seat Cushion Foam Pad Removal Note Locations View 151-14 A/T - Erratic Fluid Level Readings/Filler Tube Leaks Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T - Erratic Fluid Level Readings/Filler Tube Leaks TSB 06-18-13 09/18/06 ERRATIC FLUID LEVEL READING ON TRANSAXLE DIPSTICK - LEAKS - 4F50N, AX4N, AX4S FORD: 2000-2007 Taurus 2000-2007 Windstar 2004-2007 Freestar MERCURY: 2000-2005 Sable 2004-2007 Monterey This article supersedes TSB 05-14-5 to update the Service Procedure and vehicle model years. ISSUE Some 2000-2007 Taurus, 2000-2005 Sable, 2000-2003 Windstar, and 2004-2007 Freestar/Monterey vehicles, equipped with a 4F50N, AX4N, or AX4S transaxle, may exhibit an erratic fluid level reading on the transaxle dipstick and possible leaks around the filler tube and grommet. The condition may be due to a restricted transaxle vent. ACTION Repair the transaxle vent restriction by replacing the transaxle vent with a 90° vent stem, small hose clamp, two (2) tie raps, and 24" (61 cm) of 5/16" (8 mm) vacuum hose. The 5/16" (8 mm) vacuum hose will be routed from the 90° vent on the transaxle back to the cowl area, next to the brake master cylinder and tie rapped in place with the end of the hose facing down. Refer to the following Service Procedures. NOTE ON WINDSTAR, FREESTAR AND MONTEREY SEAL THE COWL PANEL GRILLE (COWL TO VENT PANEL) AREA, SEE TSB 06-14-10. NOTE LEAKS MAY BE MISDIAGNOSED AS COMING FROM THE PAN GASKET. ALWAYS FOLLOW WORKSHOP MANUAL, SECTION 307-01 TO LOCATE THE SOURCE OF A LEAK, AND LEAK CHECK WITH BLACK LIGHT AND DYE. SERVICE PROCEDURE 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Disconnect the crankcase vent tube(s) from the air cleaner outlet pipe. 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body. 4. Release the air cleaner housing clamp(s). 5. Separate the air cleaner cover from the air cleaner tray. 6. Windstar, Freestar and Monterey only: Remove cowl panel grille by following the procedure in TSB 06-14-10. 7. Disconnect the shift cable if located over the top of the vent. 8. Remove the vent, pull straight up on the vent with locking pliers, or carefully pry the vent from the transaxle case. 9. Install the replacement 90° vent stem. Locations View 151-2 P0147 P0145 - P0149: Testing and Inspection P0147 For diagnosis of code P0147 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5627 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Component Locations Page 928 P1125 - P1129: Testing and Inspection P1128 For diagnosis of code P1128 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Specifications Fluid Pan: Specifications Fluid pan-to-case (lower reservoir) ............................................................................................................................................................. 12 Nm (9 ft. lbs.) Page 7899 Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING NOTE: All remote transmitters must be programmed at the same time. 1. The vehicle must be electronically unlocked before entering program mode (via remote transmitter, keyless entry keypad (if equipped) or door lock control switch while the driver door is open. 2. Turn the key from OFF to RUN 8 times within 10 seconds, with the eighth turn ending in RUN. If the module has successfully entered program mode, it will lock and then unlock all doors. 3. Within 20 seconds, press any button on a remote transmitter, and the doors will lock and then unlock to confirm that each remote transmitter has been programmed. Repeat this step for each remote transmitter. 4. If the door locks do not respond for any remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. Make sure that no more than the maximum number of remote transmitters are attempted to be programmed. 5. Exiting the programming mode is accomplished if one of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last remote transmitter was programmed. - The maximum number of remote transmitters have been programmed. Page 5342 2. NOTE: If necessary, use a nonmetallic mallet to aid in seating the circlip in the differential side gear groove (RH) or output shaft splines (LH). Tap only on the outboard front wheel halfshaft joint. Align the inboard CV Joint housing splines with the differential side gear splines (RH) or output shaft splines (LH), and push the inboard CV joint housing assembly inward until the circlip seats in the differential side gear (RH) or inboard CV joint housing (LH). 3. Align the halfshaft outboard CV joint splines and the wheel hub splines, and push the joint into the wheel hub as far as possible. 4. Install the washer and the original wheel hub retainer. Using the old retainer, seat the outboard CV joint in the hub. Remove the retainer and discard it. Item 3: Lower Control Arm Ball Joint Pinch Bolt Installation Note 1. CAUTION: Install a new bolt and nut. Connect the suspension lower arm to the knuckle and install the new bolt and nut. Page 3453 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. A related DTC will also be set when this fault 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 cam 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 two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Page 6262 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 1654 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 2 Page 7459 With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. Item 1: Seat Cushion Pan Installation Note 1. Bend the retaining ear back on the pressure sensor component bracket. Item 2: Bladder, Occupant Classification Sensor (OCS) Installation Note 1. CAUTION: - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Engine Controls, A/T - Various Driveability Issues/DTC's Firewall: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 1994 Page 7451 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 7983 Test A4 Continued Normal Operation The HomeLink(R) universal transmitter is integral to the left sun visor assembly. Under normal operation the HomeLink(R) universal transmitter can be programmed to operate up to three garage doors, entry gates, security systems, and home or office lighting. Voltage is provided to the vanity mirror through circuit 53 (BK/LB). Circuit 1205 (BK) supplies the vanity mirror ground. Possible Causes - circuit 53 (BK/LB) open or short to ground - circuit 1205 (BK) open - receiver unit - HomeLink(R) universal transmitter Page 1325 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1740 refer to chart Page 7662 Locations View 151-16 Page 7413 View 151-29 Page 522 P0455 - P0459: Testing and Inspection P0457 For diagnosis of code P0457 refer to the system experiencing the problem. Computers and Control Systems P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7640 Part 2 Locations View 151-9 Page 3855 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 1497 P2270 - P2274: Testing and Inspection P2273 For diagnosis of code P2273 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Liftgate Ajar Switch Page 4071 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 9555 Test W6-W8 Page 7585 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 675 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4079 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Page 8638 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the driver seat. Page 1655 Page 3510 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Power Window Motor, Left Front View 151-18 Page 8140 Page 4187 14-2 Page 3885 Intake Air Temperature Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Auxiliary Relay Box Page 7599 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 7500 Special Tool(s) Page 4330 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Page 3560 Page 314 Inspection Page 3641 Page 729 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Connector Views Engine Control Module: Connector Views Page 7136 1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about two minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat steps 3 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Page 289 Inspection Page 296 Inspection Page 479 P0405 - P0409: Testing and Inspection P0406 For diagnosis of code P0406 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2539 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 1379 P1785 - P1789: Testing and Inspection P1789 For diagnosis of code P1789 refer to chart P0740-P1789 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 4853 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8751 Page 3599 Heater Core: Description and Operation Auxiliary Climate Control HEATER CORE The auxiliary climate control system uses a rear heater core which operates in the same manner as the front heater core. Page 1710 Page 3128 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: Never run the engine with one wheel off the ground, such as when changing a tire. The wheel still on the ground could cause the vehicle to move. CAUTION: - The jack provided with the vehicle is intended to be used in an emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to lift the vehicle for any other purpose. Refer to the Owner Literature when using the jack supplied with the vehicle. - Under no circumstances should the vehicle ever be lifted by the front control arms, front I-braces, suspension arm brackets, rear stabilizer or differential housing. Severe damage to the vehicle could result. - Do not attempt to use jack pressure on either the front bumper or the rear bumper of any vehicle. Damage to the bumper covers will occur. Lift the vehicle using the following procedure. Jacking Points Jacking Points To lift the front or either side of the front end, position the floor jack or the hoist under the front frame lift points. To lift the rear or either side of the rear end, position the floor jack or the hoist under the rear lift points. LIFTING CAUTION: - Do not allow the lift adapters to contact the steering linkage, suspension arms, front I-braces, stabilizer bar, or to compress the lower suspension arm stabilizer bar insulator. Damage to the suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the lift adapters prior to lifting the vehicle. - Never use the differential housing as a lift point. Damage to the differential housing and cover may occur. - Do not lift the vehicle on the rocker panel pinch flange except at the designated lift points or body damage may occur. Lift the vehicle using the following procedure. Lifting Points-Drive-On Hoist Page 4878 Page 9190 Symbols Part 5 Page 618 Inspection Page 4460 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 8142 Body - Cowl Panel Grille Breakage Cowl: All Technical Service Bulletins Body - Cowl Panel Grille Breakage TSB 04-17-6 09/06/04 COWL PANEL GRILL BREAKING FORD: 1999-2003 Windstar 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 1999-2003 Windstar and 2004-2005 Freestar/Monterey vehicles may exhibit the windshield cowl panel grille (leaf screen) breaking at the grille opening. ACTION To service, replace cowl panel with updated service part. Refer to Workshop Manual Section 501-02. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041706A Replace The 0.3 Hr. Windshield Cowl Panel Grille (Leaf Screen) DEALER CODING CONDITION BASIC PART NO. CODE 70022A68 01 Disclaimer System Diagnosis P1520 - P1524: Testing and Inspection For diagnosis of code P1520 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1875 Locations View 151-6 Page 1209 Inspection LH Side Power Sliding Door Module: Diagrams LH Side Parking Aid Speaker, Front Page 7935 Parking Assist Distance Sensor: Diagrams Page 2666 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2425 Locations View 151-6 Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill Material 1. With the engine running, check the transmission fluid level and condition. If the fluid level and fluid condition is not within specification, adjust to correct level. For additional information, refer to Preliminary Inspection. See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Initial Inspection/Preliminary Inspection 2. Turn the engine OFF. 3. With the vehicle in NEUTRAL, position it on a hoist. 4. Remove the lower retaining clip from the lower transaxle cooler line fitting. 5. Depress the tabs on the plastic insert retainer and remove cooler line from fitting. 6. Attach a flexible hose, approximately 0.9 mm (3.0 ft.) in length, to the fluid cooler tube with the other end in a suitable, 15-quart container. Diagrams Trunk / Liftgate Motor: Diagrams Page 3321 1. Slide the A/C compressor toward the engine and tighten the mounting bolts. Item 5: RH Engine Mount Nut Installation Note 1. Using the special tools, lower the engine. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 3197 Part 1 Of 3 Part 2 Of 3 Page 3962 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 404 P0315 - P0319: Testing and Inspection P0316 For diagnosis of code P0316 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5073 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Service Precautions Fuel Injector Wiring Harness: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 3405 CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the generator. 3. Remove the coolant pump. 4. Remove the camshaft synchronizer. 5. Remove the parts in the order indicated in the illustrations and tables. Part 1 Of 3 Part 2 Of 3 Page 6716 Part 2 Of 2 3. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. 5. Fill and leak test the system. 6. Check and, if necessary, adjust the front end alignment. Item 1: Outer Tie-Rod Removal Note 1. Using the special tool, separate the tie-rod end from the wheel knuckle. Item 9: Steering Gear Removal Note 1. Remove the steering gear through the left side wheel well. Item 9: Steering Gear Installation Note 1. Install a new steering gear through the left side wheel well. Item 6: O-Ring Installation Note 1. Using the special tool, install new [email protected] seals onto the power steering hoses. Page 137 P0130 - P0134: Testing and Inspection P0134 For diagnosis of code P0134 refer to chart P0107-P0193 Page 8630 Page 8885 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 2: Speed Control Deactivator Switch Removal Note 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Remove the speed control deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. Item 2: Speed Control Deactivator Switch Installation Note 1. After the deactivator switch is installed, it is necessary to bleed the brake system. Page 9341 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 4591 Three-Way Catalytic Converter The three-way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-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. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) 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 it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Page 559 P0505 - P0509: Testing and Inspection P0506 For diagnosis of code P0506 refer to chart P0505-P0722 NOTE 9: Refer to the Description, Possible Causes and Diagnostic Aids for the DTC in question. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle Locations Page 7494 2. CAUTION: Use care when separating the seat back trim cover from the hook and loop strip, or the hook and loop strip could be torn from the seat back foam. Invert the backrest trim cover in an inside out fashion to the row of hog rings. Placing a hand between the seat backrest trim cover and pad, carefully separate the hook and loop strips. 3. Release the side air bag module deployment chute clip. Item 23: Side Air Bag Module Harness Removal Note 1. Separate the side air bag module wire harness pin-type retainers. Route out the wire harness, making note of the routing for installation. Item 25: Side Air Bag Module Removal Note 1. WARNING: Do not disconnect the wire connector at the seat side air bag module. This is a permanent connection. Doing so may result in accidental air bag deployment, which may result in personal injury. Pulling the backrest foam pad aside, remove the side air bag module with wire harness. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. Specifications Ball Joint: Specifications Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Reference Diagram ............................................................................................................................. ............................................................................. D Page 540 P0480 - P0484: Testing and Inspection P0481 For diagnosis of code P0481 refer to chart P0463-P0503 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1537 Page 8561 Page 6557 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Page 3077 Locations Page 3824 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 7272 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 4241 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 1029 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1265 refer to chart Locations View 151-2 Page 168 Inspection Page 9043 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 3900 View 151-6 Page 8257 1. Using the special tool, install the new rivets. Page 2886 4. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Page 5670 Page 9259 Page 8996 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 2233 Page 6616 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Locations Page 7030 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions corresponding to the coupling size. 3. Assemble the pad to the tool. 4. Coat the abrasive pad with mineral oil. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and free of scratches or foreign material. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component. Page 7307 Heating and Ventilation Heater Core: Description and Operation Heating and Ventilation HEATER CORE The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 1514 P2700 - P2704: Testing and Inspection P2704 For diagnosis of code P2704 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2717 View 151-9 System Diagnosis P1550 - P1554: Testing and Inspection For diagnosis of code P1550 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7474 Special Tool(s) Page 8653 Part 1 Page 7467 2. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 17: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 18: Electrical Connector Removal Note 1. Disconnect the occupant classification sensor and remove any retainers from its wiring harness. Item 21: Occupant Classification Sensor (OCS) Removal Note Page 1813 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Specifications Brake Fluid: Specifications Brake Fluid Type High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 Description and Operation Fuel Filler Cap: Description and Operation FUEL CAP OFF INDICATOR LAMP The Fuel Cap Off Indicator Lamp (FCIL) is an output signal that is controlled by the PCM and will illuminate when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed properly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. NOTE: The Escape, Freestar/Monterey, Mustang, Thunderbird, Town Car, Lincoln LS6/LS8, Expedition and Navigator do not have a dedicated (separate) output wire from the PCM to the instrument cluster. The PCM commands the FCIL on and off through the BUS +/- circuits (SCP). Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Page 6465 Page 9741 Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 3370 Lower Intake Manifold Torque Sequence 3. Tighten the lower intake manifold bolts in two stages in the sequence shown. - Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 10 Nm (89 inch lbs.). Page 394 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 138 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3794 Removal and Installation Seat Belt: Service and Repair Removal and Installation Front Safety Belt FRONT SAFETY BELT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - All safety belt assemblies including retractors, buckles, shoulder belt height adjusters (if so equipped) child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. - The safety belt buckle pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - After deployment, the air bag surface could contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. CAUTION: It is necessary to rezero the occupant classification sensor (OCS) system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: Right side shown, left side similar. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or Locations View 151-10 Page 131 P0130 - P0134: Testing and Inspection P0132 OBD II - Base Gasoline For diagnosis of code P0132 refer to chart P0112-P0147 If there is no link in the chart then: Page 4506 View 151-6 LH Side Power Sliding Door Module: Diagrams LH Side Page 2626 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Service and Repair Rocker Arm Assembly: Service and Repair Rocker Arms, Valve Springs, Push Rods, Valve Tappets Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location. 1. Remove the valve cover. 2. If removing the valve tappets, remove the lower intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 245 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0193 refer to chart Page 1264 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4409 Locations Page 288 P0205 - P0209: Testing and Inspection P0209 For diagnosis of code P0209 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7271 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 910 P1115 - P1119: Testing and Inspection P1117 For diagnosis of code P1117 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7771 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Page 8101 Symbols Part 4 Page 4829 Part 2 5. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps. Item 3: Fuel Filler Pipe Pin-Type Retainer Removal Note 1. Remove the LH rear wheel well inner splash shield. Page 3410 2. Rotate the crankshaft until the timing marks and keyways align. 3. Compress and install a retaining pin to hold the timing chain tensioner. 4. Remove the camshaft gear, crankshaft gear and the timing chain as an assembly. 5. Remove the bolts and the timing chain tensioner. Items 23-17: Timing Components Installation Note P1512 P1510 - P1514: Testing and Inspection P1512 For diagnosis of code P1512 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-8 Engine Cooling Fan Relay 1 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 1 Customer Safety Information Child Seat Tether Attachment: Customer Safety Information WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification. Otherwise, the child safety seat may not be correctly secured and the child could be injured if the vehicle is involved in a collision or stops suddenly. Locations View 151-6 Page 5936 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 455 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4251 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Description and Operation Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITORING SYSTEM (TPMS) Your vehicle may have a temporary spare tire. The temporary spare tire for your vehicle is labeled as such. It is smaller than a regular tire and is designed for emergency use only. Replace this tire with a full-size tire as soon as possible. Note: The Low Tire Pressure Warning system (if equipped) will detect the temporary spare tire and illuminate the low tire warning light until the spare tire is replaced with a proper full-size tire. Page 8946 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. Description and Operation Exhaust Pipe: Description and Operation 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. Page 8845 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Page 4813 Fuel Rail: Description and Operation Fuel Rail Fuel Rail Components The fuel rail (Figure 80) distributes low pressure fuel from the chassis supply line to each fuel injector. Fuel pressure at the top of each fuel injector is maintained within 1% of the other fuel injectors at all times; this is done with nearly symmetric flow paths. The fuel rail is also designed to have minimal flow restriction by increasing the cross-sectional flow area and reducing the flow path length. The fuel rail contains several other parts in assembly (PIA) components that perform crucial functions. These include: - Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. - Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. - Low pressure solenoid shut-off valve which isolates the fuel rail from the upstream fuel system when the engine is OFF. This minimizes the amount of fuel available to flow through the fuel injectors when the engine is off or leak from a damaged fuel rail during and after a crash. The valve is controlled by the PCM fuel shut-off valve circuit and contains an inertia switch. The valve is only on for one second after a key-on or whenever CKP signals are being received by the PCM. - schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 1608 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 452 P0355 - P0359: Testing and Inspection P0357 For diagnosis of code P0357 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7894 Keyless Entry Key-Pad: Service and Repair Removal And Installation KEYLESS ENTRY KEYPAD REMOVAL 1. Remove the front door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 931 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8341 14. Reconnect the 2 rear window defrost electrical connectors. Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 3230 1. Install the rocker arms. - Position the rocker arms and pivots. - Hand-start the bolts. - Tighten the bolts in two stages. Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 32 Nm (24 ft. lbs.). Specifications Idle Speed: Specifications Idle Speed is Computer Controlled Hot Idle ................................................................................................................................................ .............................................................. 700-730 rpm Page 2991 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM EVACUATION AND CHARGING Special Tool(s) SPECIAL TOOL(S) Refrigerant System Evacuation Using an R-134a Service Center NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Page 5061 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 8685 Page 3551 2.0L Escape: PCM FC Output State For Cooling Fan Speeds Chart Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds Chart For three speed fans, although the PCM output circuits are called low, medium and high fan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 7522 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 4793 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 6297 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 1369 P1780 - P1784: Testing and Inspection P1783 4R70W For diagnosis of code P1783 refer to chart Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Locations View 151-28 Page 4874 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) REMOVAL 1. Remove the LH lower B-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Service Precautions Coupler HVAC: Service Precautions CAUTION: - Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the O-ring seal grooves, resulting in refrigerant leaks. - Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks. - Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. - Support the female fitting with a wrench to prevent the tubes from twisting. - Use only the new O-ring seals. The use of any O-ring seals other than those specified in the Ford Master Parts Catalog may result in intermittent leakage during vehicle operation. Page 2398 Fuel Pressure Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5511 Page 1815 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 7588 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 8311 2. Remove the parts in the order indicated in the illustration and table. Item 1: Sliding Door Window Glass Removal Note WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. 1. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. Page 6498 Page 5402 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Page 1065 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6110 Note: The bussed electrical center is located in the engine compartment. Page 5877 Part 2 Of 2 3. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed stems: 4. To install, reverse the removal procedure. 5. Bleed the brake system. For additional information, refer to Brake System Bleeding. 6. Inspect the brake system for proper operation. Item 3: Brake Tube Fittings Removal Note 1. Cap the brake line and plug the master cylinder ports. Item 5: Brake Master Cylinder Removal Note 1. Use a suitable suction device to drain the reservoir before removal. 2. If removing the brake booster, position the brake master cylinder forward. Item 14: Brake Booster Removal Note Page 6528 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Locations View 151-6 Page 7480 View 151-14 Page 9281 Page 8644 Part 1 Page 686 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 8508 Page 4472 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Brakes - Accelerated rear Brake Pad Wear Brake Pad: Customer Interest Brakes - Accelerated rear Brake Pad Wear TSB 04-26-10 12/31/04 REAR BRAKE LINING ACCELERATED WEAR FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit accelerated rear brake pad lining wear, heavily scored rear rotors, or metal pickup in the rear lining. ACTION Replace the rear brake pad linings, machine the rotors as required. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042610A 2004-2005 0.7 Hr. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads Only 042610B 2004-2005 1.6 Hrs. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads, Machine Both Rear Brake Rotors On Vehicle DEALER CODING CONDITION BASIC PART NO. CODE 2200 42 Disclaimer System Diagnosis P1900 - P1904: Testing and Inspection For diagnosis of code P1900 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6123 Page 1921 Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Page 1612 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. For module configuration and calibration, refer to Module Communications Network. 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU). 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 8163 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 1789 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Door Ajar Switch, Left Front View 151-18 Trailer Tow Relay, Right Turn Page 9456 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 4097 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two 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 percent of the highest reading. Page 4763 1. Cut the nylon tie-straps and remove the wiring harness. INSTALLATION 1. To install, reverse the removal procedure. - Install new nylon tie-straps. Page 1886 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 1740 Specifications Brake Pedal Assy: Specifications Adjustable pedal motor bolts ............................................................................................................... .................................................... 2 Nm (18 inch lbs.) Brake pedal bracket bolts ................................ ......................................................................................................................................... 25 Nm (18 ft. lbs.) Page 12 P0010 - P0014: Testing and Inspection P0012 For diagnosis of code P0012 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5221 6. If fluid contamination or transaxle failure is confirmed by the sediment in the bottom of the fluid pan, the transaxle must be disassembled and completely cleaned. This includes the torque converter, cooler bypass valve, coolers and cooler lines. 7. Carry out diagnostic checks and adjustments. Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures Page 5866 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 651 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4646 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Page 6103 Locations View 151-6 Page 9350 Symbols Part 5 Page 1372 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift For diagnosis of code P1783 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Locations View 151-2 Page 3906 Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation FUEL CAP OFF INDICATOR LAMP The Fuel Cap Off Indicator Lamp (FCIL) is an output signal that is controlled by the PCM and will illuminate when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed properly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. NOTE: The Escape, Freestar/Monterey, Mustang, Thunderbird, Town Car, Lincoln LS6/LS8, Expedition and Navigator do not have a dedicated (separate) output wire from the PCM to the instrument cluster. The PCM commands the FCIL on and off through the BUS +/- circuits (SCP). Page 6911 Page 2457 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Service Precautions Evaporator Case: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Page 2027 Page 1894 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Power Point, C Pillar Page 7992 INSTALLATION 1. To install, reverse the removal procedure. Item 3: Driver Seat Module (DSM) Installation Note 1. Once the DSM is installed, it is necessary to download the module configuration information from the diagnostic tool into the new module. Auxiliary Blower Motor Relay Page 8944 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 Page 5729 Brake Caliper: Specifications Front Brake caliper anchor bracket bolts ................................................................................................................................................... 185 Nm (136 ft. lbs.) Caliper bolts .............................................................................................................. ........................................................................... 35 Nm (26 ft. lbs.) Rear Brake caliper anchor bracket bolts ..................................................................................................................................................... 102 Nm (75 ft. lbs.) Caliper bolts ................................................................................................................ ......................................................................... 33 Nm (24 ft. lbs.) Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The Generation II (Gen II) Torque Based Electronic Throttle Control (ETC) is a hardware and software strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes an electronic throttle body, the PCM and a accelerator pedal assembly to control throttle opening and engine torque. The ETC system basically replaces the standard cable operated accelerator pedal, idle air control (IAC) motor, 3-wire throttle position sensor (TPS) and mechanical throttle body Background "Why Torque Based ETC" 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: VCT (deliver same torque during transitions) - Hybrid Electric Vehicle (HEV) Torque based ETC also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: Eliminate cruise control actuators - Eliminate Idle Air Control (IAC) Bypass actuator - Better airflow range - Packaging (no cable) - More responsive powertrain at altitude and improved shift quality It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. Electronic Throttle Body (ETB) The Gen II electronic throttle body (Figure 133) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2 times stronger than the main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (48 Km). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to avoid the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle and idle quality and eliminates the need for IAC bypass actuator. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires four wires. 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, Page 7368 Page 2357 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 4565 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 3080 Smart Junction Box (SJB) Page 5570 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 7172 Page 3711 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Service and Repair Front Steering Knuckle: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. Page 3792 Page 2224 In-Vehicle Temperature Sensor - EATC Page 6313 Page 8973 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 6457 Page 3604 Part 1 Page 635 Horns NOTE 16: REFER to Exterior Lighting component testing in Lighting and Horns for further diagnosis of the Smart Junction Box (SJB). Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Lighting and Horns NOTE 17: REFER to Antilock Brakes / Traction Control Systems, for further diagnosis of the cause of the incorrect brake pedal status from the ABS to the PCM. Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Cruise Control Related Diagnosis For diagnosis of code P0703, refer to chart: P0500-P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Cruise Control system, follow this link: See: Cruise Control/Testing and Inspection Electrical - ABS/TCS/Park Brake Lamps Flickering Traction Control Indicator Lamp: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 5792 Page 5642 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 9540 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 Page 8104 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 Page 7099 4. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. Pull the heater hose away from the heater core tube. 5. Spread the retainer tabs apart and slide the retainer off the tube. - Discard the retainer. CONNECT 1. Clean the tubes and lubricate with coolant hose lubricant or plain water. 2. Install a new coupling retainer into the heater hose coupling housing. 3. Push the heater hose coupling onto the tube. 4. Make sure the heater hose coupling is fully engaged by lightly pulling on the heater hose. Page 1683 Page 3290 1. Install the rocker arms. - Position the rocker arms and pivots. - Hand-start the bolts. - Tighten the bolts in two stages. Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 32 Nm (24 ft. lbs.). Page 2146 View 151-4 Page 3865 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 320 P0230 - P0234: Testing and Inspection P0231 For diagnosis of code P0231 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 671 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0715 refer to chart Page 1649 Locations View 151-6 Page 5867 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 1. Remove the battery tray. 2. Raise and support the vehicle. Page 6490 Page 1183 P1500 - P1504: Testing and Inspection P1504 For diagnosis of code P1504 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and P1751 P1750 - P1754: Testing and Inspection P1751 For diagnosis of code P1751 refer to chart P0740-P1789 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 946 P1135 - P1139: Testing and Inspection P1138 For diagnosis of code P1138 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7916 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Bussed Electrical Center (BEC) Fuse Block: Application and ID Bussed Electrical Center (BEC) Page 1984 Parking Assist Distance Sensor: Locations View 151-4 Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: Customer Interest Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Page 1778 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 3338 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil. Item 1: Drain Plug And Gasket Removal Note 1. Allow the engine oil to drain. Item 7: Oil Pan Removal Note 1. Clean the oil pan mating surfaces with metal surface cleaner. Items 8-6: Oil Pan Installation Note Page 7516 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 4398 Service and Repair Lateral Accelerometer: Service and Repair Accelerometer Removal and Installation NOTE: When installing a new accelerometer, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. 1. Remove the driver side front seat. 2. Remove the lower B-pillar trim panel. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: Electrical Connector Removal Note 1. Fold back the carpeting flap to gain access to the accelerometer. Page 8429 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 3301 1. Install the rocker arms. - Position the rocker arms and pivots. - Hand-start the bolts. - Tighten the bolts in two stages. Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 32 Nm (24 ft. lbs.). Page 6112 Fuse: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 9382 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Trailer Tow Relay, Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 359 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6845 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Page 4720 Symptom Chart Page 2993 Refrigerant Identifier With Air-Radicator Page 7583 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 936 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 312 Inspection Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Testing and Inspection Micro ISO Relay: Testing and Inspection ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 2350 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Locations View 151-15 Page 1012 Inspection Page 2084 Power Seat Switch: Testing and Inspection Seat Adjust Switch, Passenger Side Front Page 7488 Side Air Bag: Vehicle Damage Warnings CAUTION: Use care when separating the seat back trim cover from the hook and loop strip, or the hook and loop strip could be torn from the seat back foam. Page 7817 Part 2 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. Page 3009 11. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to Specifications. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the master cylinder to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all the dirt from the area and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Page 2800 Item 6: Spark Plug Wire-to-Spark Plug Removal Note 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 6926 Page 2071 Page 242 Inspection Locations Page 50 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5021 Four-Tower Coil Packs Diagrams Page 952 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3425 2. Remove the catalyst monitor sensor electrical connector mounting bracket. Item 13: Engine Front Cover Cap Screw Removal Note 1. CAUTION: The cap screw is hidden by the oil filter housing. Failure to remove this retainer will result in damage to the engine front cover. Remove the engine front cover cap screw. Items 14-15: Engine Front Cover and Stud Removal Note 1. NOTE: Mark the studs so they can be reinstalled in their original location. Loosen the engine front cover studs and remove them with the engine front cover. Items 17-23: Timing Components Removal Note 1. Remove the synchronizer drive gear. 1. Remove the bolt. 2. Remove the synchronizer drive gear. Page 9722 Page 7982 Garage Door Opener Transmitter: Pinpoint Tests LH Vanity Mirror Lamp Test A PINPOINT TEST A: THE UNIVERSAL TRANSMITTER IS INOPERATIVE Test A1-A4 Page 5220 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the DO NOT DRIVE mark or internal failure could result. If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot weather or while pulling a trailer, the fluid needs to cool down to obtain an accurate reading. The fluid level reading on the fluid level indicator will differ depending on operating and ambient temperatures. The correct reading should be within the normal operating temperature range. Fluid Level Check Under normal circumstances the fluid level should be checked during normal maintenance. If the transaxle starts to slip, shifts slowly, or shows signs of fluid leaking, the fluid level should be checked. 1. With the transaxle in (P) PARK, the engine at idle, foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever in the PARK position. 2. Wipe the fluid level indicator cap and remove the fluid level indicator. 3. Wipe the fluid level indicator with a clean cloth. 4. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating range. High Fluid Level A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube, and possible transaxle malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. See: Transmission Fluid Drain and Refill Low Fluid Level A low 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 Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transaxle malfunction and/or damage. If fluid needs to be added, add fluid in 0.25 Liters (1/2 pint) increments through the filler tube. Do not overfill the fluid. For fluid type, refer to the specification chart. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator over a white facial tissue and allow the 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 the stain is a foamy pink color this may indicate coolant in the transaxle. The engine cooling system should also be inspected at this time. Drivetrain - Outer CV Joint(s) Broken Constant Velocity Joint: All Technical Service Bulletins Drivetrain - Outer CV Joint(s) Broken TSB 05-9-8 05/16/05 OUTER CV JOINT BROKEN - VEHICLES BUILT BEFORE 5/1/2005 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles built before 5/1/2005, may exhibit a broken outer C/V joint. This may occur when the vehicle steering is turned hard in one direction and the vehicle is accelerated at a high rate. ACTION Replace the outer C/V joint and install restrictors between the inner tie-rod ends and the steering rack. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Replace the halfshaft (right and/or left). Refer to Section 205-04 of the Workshop Manual. 2. Remove the steering gear. Refer to Section 211-00 of the Workshop Manual. If present, note the orientation of the steering gear vent tube. During reinstallation the bellows and vent tube must be installed in the correct orientation. NOTE THE BELLOWS AND CLAMPS ON THE STEERING GEAR ARE DESIGNED TO PROVIDE AN AIRTIGHT SEAL TO PROTECT THE INTERNAL COMPONENTS. IF THE BELLOWS SEAL IS NOT AIRTIGHT THE VACUUM GENERATED DURING TURNING WILL DRAW WATER AND CONTAMINATION INTO THE GEAR CAUSING PREMATURE WEAR. ZIP TIES DO NOT PRODUCE AN AIRTIGHT SEAL AND MUST NOT BE USED IN PLACE OF THE BELLOWS CLAMPS. 3. Drain any excess power steering fluid from the steering gear and clean the exterior of the gear using a suitable solvent. 4. Remove and discard the two (2) inner bellows clamps. New clamps must be installed. 5. Slide the two (2) steering gear bellows aside to allow access to the inner tie-rods. 6. Thoroughly clean any abrasive material from the inside of the bellows area. Thoroughly clean and inspect all the parts being reused. 7. Install the restrictors on each side of the rack between the inner tie-rod and the steering gear housing (Figure 1). 8. Position two (2) new inner bellows clamps onto the steering gear. DO NOT secure the inner bellows clamps at this point. 9. Install the two (2) steering gear bellows over the steering gear. Page 1732 Page 2317 Turn Signal Switch: Diagrams Page 223 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0182 refer to chart Page 7323 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 9572 Locations Heated Seat Module, Passenger Side Front Page 7073 Heater Core: Description and Operation Auxiliary Climate Control HEATER CORE The auxiliary climate control system uses a rear heater core which operates in the same manner as the front heater core. Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The Generation II (Gen II) Torque Based Electronic Throttle Control (ETC) is a hardware and software strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes an electronic throttle body, the PCM and a accelerator pedal assembly to control throttle opening and engine torque. The ETC system basically replaces the standard cable operated accelerator pedal, idle air control (IAC) motor, 3-wire throttle position sensor (TPS) and mechanical throttle body Background "Why Torque Based ETC" 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: VCT (deliver same torque during transitions) - Hybrid Electric Vehicle (HEV) Torque based ETC also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: Eliminate cruise control actuators - Eliminate Idle Air Control (IAC) Bypass actuator - Better airflow range - Packaging (no cable) - More responsive powertrain at altitude and improved shift quality It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. Electronic Throttle Body (ETB) The Gen II electronic throttle body (Figure 133) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2 times stronger than the main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (48 Km). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to avoid the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle and idle quality and eliminates the need for IAC bypass actuator. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires four wires. 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, Page 1232 P1565 - P1569: Testing and Inspection P1568 For diagnosis of P1568 refer to chart DTC Index P0500 - P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1184 Inspection Page 7308 Page 4062 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 705 P0730 - P0734: Testing and Inspection P0733 4R70W For diagnosis of code P0733 refer to chart Part 4 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Diagram Information and Instructions Seat Heater: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 8520 INSTALLATION 1. To install, reverse the removal procedure. Item 3: Driver Seat Module (DSM) Installation Note 1. Once the DSM is installed, it is necessary to download the module configuration information from the diagnostic tool into the new module. P1760 P1760 - P1764: Testing and Inspection P1760 4R70W For diagnosis of code P1760 refer to chart Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle Page 6227 Page 8745 View 151-19 Page 7371 Air Bag Resistor: Service and Repair SAFETY CANOPY BRIDGE RESISTOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 6075 View 151-7 Page 7176 Page 3619 5. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Disconnect the heater hoses at the floorpan bracket. 6. Support the rear axle with a jack stand. 7. Remove the track bar bolt. 8. Disconnect the LH rear wheel speed sensor electrical connector. 9. Remove the bolts and the two remaining line brackets. 10. Tilt the auxiliary heater outlet and inlet lines to drain any remaining coolant and remove the auxiliary heater outlet and inlet lines. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only, if needed. Page 757 P0755 - P0759: Testing and Inspection P0757 For diagnosis of code P0757 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 2256 Fuel Pump Module (For Returnable Fuel Systems) Page 1454 P2120 - P2124: Testing and Inspection P2123 For diagnosis of code P2123 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 379 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2662 Page 6304 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Page 3020 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 2063 Page 4997 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 7773 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Page 2680 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 1298 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4242 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 9471 Hazard Warning Switch: Diagrams Power Point, C Pillar Diagrams Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY Special Tool(s) SPECIAL TOOL(S) Refrigerant System Recovery NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Service and Repair Shift Interlock Cable: Service and Repair Transmission Selector Cable 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Items 1 and 2: Transmission Selector Cable End and Retainer Removal Note 1. Remove the transmission selector cable from the bracket. 1 Disconnect the transmission selector cable end from the manual lever. 2 Push the lock tab and separate the transmission selector cable from the bracket. 3 Position the transmission selector cable out of the way. Page 4159 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). System Diagnosis P0345 - P0349: Testing and Inspection For diagnosis of code P0345 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4232 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 1422 P2070 - P2074: Testing and Inspection P2071 For diagnosis of code P2071 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6203 Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module Page 7383 Clockspring Assembly / Spiral Cable: Service and Repair CLOCKSPRING Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be replaced, not repainted. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect Page 4703 Symbols Part 5 Page 7764 Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The left side is shown, the right side is similar. - The first row side impact sensors are located under the seat beneath the carpet. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Page 153 P0140 - P0144: Testing and Inspection P0144 For diagnosis of code P0144 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7918 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 7389 Part 1 Part 2 2. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Install the parts in the order indicated in the illustration and table. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the steering wheel removal and installation procedure. Install the steering wheel. Do not connect the driver air bag module electrical connector at this time. 4. Through the steering wheel access door, attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 5. Connect the battery ground cable. 6. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. Page 4424 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Diagrams Page 9433 Page 9378 Parking Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 8966 Compass: Adjustments Vehicle Demagnetizing VEHICLE DEMAGNETIZING CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth covers the front third and the entire width of the roof. NOTE: - The demagnetizing process requires the use of a demagnetizing coil commonly used by television repair technicians to demagnetize television tubes. - To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained in the vehicle. - During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite the handle) is closest to the vehicle surface. 1. Demagnetize the front third of the vehicle roof. 1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle. 2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the entire surface of the vehicle roof closest to the windshield. Continue the circular motion 4 times. 3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from the vehicle. 4 Turn the demagnetizer off. 2. Carry out the Compass Zone Adjustment procedure. Refer to Compass Zone Adjustment. 3. Carry out the Compass Calibration Adjustment procedure. Refer to Compass Calibration. Page 3793 Main Relay (Computer/Fuel System): Testing and Inspection Page 8093 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Service and Repair Fan Shroud: Service and Repair REMOVAL AND INSTALLATION Radiator, Cooling Fan and Shroud Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the transmission fluid cooler. Part 1 Of 2 Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Page 6499 Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity With Auxiliary Heater ........................................................................................................................... .................................................. 16.0 qts (15.1 L) Without Auxiliary Hearet ........................................ ................................................................................................................................ 15.0 qts (14.2 L) Page 3879 Fuel Pressure Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Locations View 151-5 Electrical - ABS/TCS/Park Brake Lamps Flickering Wiring Harness: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 787 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0781 refer to chart Page 4982 Page 3770 Main Relay (Computer/Fuel System): Testing and Inspection Page 8994 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 9505 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 6046 Part 1 Page 6215 Page 7590 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. P2121 P2120 - P2124: Testing and Inspection P2121 For diagnosis of code P2121 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6428 Page 1129 Inspection Page 5323 21. CAUTION: Do not remove the two bolts that hold the pump assembly and main control valve body together as the pump assembly may fall from the main control valve body and become damaged. CAUTION: Only four of the six bolts need to be removed. Remove the bolts. Note the size and location of the bolts. 22. Disconnect the manual linkage. 23. Remove the main pump assembly and the main control valve body by carefully sliding it off the pump shaft. Installation 1. Install the pump assembly and main control valve body onto the pump shaft. 2. Rotate the pump assembly and main control valve body to connect the manual valve link with the manual valve. Page 4713 Accelerator Pedal: Connector Views Page 6502 Relay Box: Application and ID Bussed Electrical Center (BEC) Page 385 P0295 - P0299: Testing and Inspection P0298 For diagnosis of code P0298 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9575 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Parking Lamp Trailer Tow Relay, Right Turn Page 8475 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Page 3588 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Page 4185 Page 9 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 5207 Page 8723 Door Position Switch: Diagrams Sliding Door Contact Switch, Left Page 5013 Item 6: Spark Plug Wire-to-Spark Plug Removal Note 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Page 244 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0193 refer to chart Page 469 Inspection Page 8094 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 252 Inspection Page 9609 THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS EXPLAINED IN THIS ARTICLE. Examples Of Non-Warrantable Grid Line Damage ^ Ice scraper damage to grid lines ^ Animal scratches on grid lines ^ Window tint film/removal of the film which damages grid lines ^ Stickers placed over grids which upon removal, removes the grid line material ^ License plate (steel type placed against the inside of back glass) which rubs on the grid line causing damage ^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal removes grid line material ^ Cargo or lumber rubbing against the glass which removes grid line material ^ Cellular phone antenna installation/removal which damages grid line material NOTE AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL ACROSS THEM. GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR 12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID LINE INOPERATIVE - DIAGNOSTICS 1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power and ground to the back-glass. 2. Connect a test lamp or DVOM to a good body ground. 3. Turn the ignition key to the run position and depress and release the rear defroster button to turn the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME THE DEFROSTER BUTTON IS PRESSED. 4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM + lead to each grid line. (Use caution not to damage grid lines). The DVOM should read approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test light, the bulb should be approximately the same brightness on each line from top to bottom. If the DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid line with the + test lead or test lamp until the voltage changes suddenly. This is the area of concern, use chalk to mark the area of concern and mark the outside of the glass at that same area. 5. Repair per the Grid Line Repair Procedure. GRID LINE REPAIR PROCEDURE NOTE LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE, HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE (5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID LINE AREAS. NOTE IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW DEFROSTER REPAIR COMPOUND. Page 4987 Firing Order: Locations Page 3236 1. Install the rocker arms. - Position the rocker arms and pivots. - Hand-start the bolts. - Tighten the bolts in two stages. Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 32 Nm (24 ft. lbs.). Recall 04V446000: Front Hub/Rotor/Bearing Replacement Brake Rotor/Disc: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 5888 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 7690 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Body - Cowl Panel Grille Breakage Cowl: All Technical Service Bulletins Body - Cowl Panel Grille Breakage TSB 04-17-6 09/06/04 COWL PANEL GRILL BREAKING FORD: 1999-2003 Windstar 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 1999-2003 Windstar and 2004-2005 Freestar/Monterey vehicles may exhibit the windshield cowl panel grille (leaf screen) breaking at the grille opening. ACTION To service, replace cowl panel with updated service part. Refer to Workshop Manual Section 501-02. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041706A Replace The 0.3 Hr. Windshield Cowl Panel Grille (Leaf Screen) DEALER CODING CONDITION BASIC PART NO. CODE 70022A68 01 Disclaimer Page 1661 Page 3540 Coolant: Fluid Type Specifications Motorcraft Premium Gold Engine Coolant VC-7-A (in California and Oregon VC-7-B) or equivalent (yellow-color) Ford Specification ................................................................................................................................ .................................................. HWSS-M97B51-A1 Note: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: All Technical Service Bulletins Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 5072 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 5793 System Diagnosis P0065 - P0069: Testing and Inspection For diagnosis of code P0068 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-6 Service and Repair Transmission Mount: Service and Repair Transaxle Support Insulator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 3569 Page 1934 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 5692 Symbols Part 2 Page 7544 Air Bag Control Module: Diagrams Page 2225 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Center Instrument Panel Finish Panel Removal Note 1. Remove the center instrument panel finish panel. INSTALLATION 1. To install, reverse the removal procedure. Page 8524 Description and Operation Fuel Gauge Sender: Description and Operation FUEL PUMP MODULE Fuel Pump Module Page 6747 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Page 7638 Torx Bit, Safety Belt Bolt SPECIAL TOOL(S) REMOVAL WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. NOTE: Lower rear quarter trim removed for clarity. Right side shown, left side similar. 1. To access the third row outboard safety belt retractor, remove the quarter trim panel. 2. To access the third row safety belt buckles, partially remove the seat cushion trim cover. 3. To remove the third row center retractor, remove the headliner. Page 6418 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 279 P0205 - P0209: Testing and Inspection P0206 OBD II - Base Gasoline For diagnosis of code P0206 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7436 Impact Sensor: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 5618 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 996 P1235 - P1239: Testing and Inspection P1237 For diagnosis of code P1237 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 2683 Locations View 151-17 Page 9064 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 5473 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Locations Page 8681 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. Page 2596 Seat Belt Buckle Switch: Description and Operation SAFETY BELT SWITCH As part of the supplemental restraint system (SRS), the driver and passenger safety belt buckles are equipped with hall-effect sensors. The safety belt switches indicate to the restraints control module (RCM) whether the safety belt buckles are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The safety belt switches are also used for the driver safety belt warning system and the driver and passenger belt minder. Refer to Seat Belt Systems. Page 7582 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Page 2910 Locations View 151-9 Page 7831 Special Tool(s) Page 6596 Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 393 P0300 - P0304: Testing and Inspection P0300 For diagnosis of code P0300 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6057 1. Position the cable boot aside to access the nut. INSTALLATION 1. To install, reverse the removal procedure. Page 6469 Relay Box: Application and ID Bussed Electrical Center (BEC) Page 3196 Wheel Bearing: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. Page 4834 Item 21: Fuel Pump Module Gasket Installation Note 1. Install a new fuel pump module gasket with a new gasket upon fuel pump module installation. Item 20: Fuel Pump Module Installation Note 1. When installing the fuel pump module, make sure to align the locator tabs on the fuel tank mounting flange. Item 19: Fuel Delivery Module Lock Ring Installation Note 1. Using the special tool, install the fuel delivery module lock ring. Items 18, 10 and 9 Fuel Supply and Vapor Tube Quick Connect Fittings Installation Note 1. CAUTION: Make sure the fuel tube clicks into place when installing the tube. To make sure the tube is fully seated, pull on the tube. NOTE: Apply clean engine oil to the end of the tube before inserting a tube into the connector. Install the fuel tube quick release coupling. Page 6255 Page 3079 Seat Adjust Switch, Driver Side Front Power Seat Switch: Testing and Inspection Seat Adjust Switch, Driver Side Front Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System INERTIA FUEL SHUTOFF (IFS) SWITCH Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 76) 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 a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Locations View 151-8 Service Precautions Memory Positioning Module: Service Precautions CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Page 6216 Page 1776 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. P0112 P0110 - P0114: Testing and Inspection P0112 OBD II - Base Gasoline For diagnosis of code P0112 refer to chart P0112-P0147 If there is no link in the chart then: Interior Trim Panels Trim Panel: Service and Repair Interior Trim Panels INTERIOR TRIM PANELS REMOVAL Page 2209 Ambient Temperature Sensor / Switch HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Ambient Temperature Sensor The ambient temperature sensor signal is received by the smart junction box (SJB) which communicates it to the EATC module via the vehicles SCP network. Page 6983 10. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 11. Install the A/C compressor. Page 6949 Page 5712 Brake Pedal Assy: Service and Repair Brake Pedal NOTE: The adjustable pedal assembly is shown, the fixed pedal assembly is similar. 1. If equipped with adjustable pedals, make sure they are in the full forward position. 2. Remove the instrument panel steering column reinforcement. Part 1 Of 3 Part 2 Of 3 Electrical - ABS/TCS/Park Brake Lamps Flickering Parking Brake Warning Lamp: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 2583 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Second Row, RH SIDE IMPACT SENSOR - SECOND ROW, RH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system Page 7311 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 4558 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 1559 Page 4857 Page 3739 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 3566 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 3 Page 8284 View 151-20 Locations View 151-3 Page 6446 Page 6314 4. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs) 1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. Page 2911 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. P1168 P1165 - P1169: Testing and Inspection P1168 For diagnosis of code P1168 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6771 Page 7786 Seat Belt Tension Sensor: Description and Operation Air Bag and Safety Belt Pretensioner SRS SAFETY BELT TENSION SENSOR The safety belt tension sensor: is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a three-wire Hall-effect sensor that is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is used by the OCS system to identify the presence of a child safety seat on the front outboard passenger seat. The safety belt tension sensor senses the tension on the safety belt assembly then provides an output to the OCS system electronic control unit (ECU), indicating that the safety belt assembly is cinched. After sensing the weight applied to the seat by the occupant and using the safety belt tension sensor input, the OCS system determines how the occupant should be classified and communicates this information to the restraints control module (RCM). If the occupant is classified to be a child, the RCM will then automatically deactivate the passenger air bag module and passenger safety belt pretensioner. Page 3614 Heater Hose: Description and Operation UNDERBODY HEATER LINES The underbody auxiliary heater lines have the following features: - The underbody auxiliary heater inlet line is a aluminum tube assembly that carries coolant from the engine coolant supply line to the auxiliary heater core inlet. - The underbody auxiliary heater outlet line carries coolant from the auxiliary heater core to the front heater core outlet line. Page 2023 Page 3092 Page 6566 Alignment: Description and Operation Suspension System Camber, caster and toe are adjustable for the front suspension system. The front camber and caster are adjusted by resetting the alignment plates on the shock towers. The front toe is adjusted at the front knuckle tie rods. 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. Part 1 Of 2 Part 2 Of 2 Caster Page 7639 Part 1 Page 1481 Inspection Page 744 P0750 - P0754: Testing and Inspection P0752 For diagnosis of code P0752 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6202 Relay Box: Locations Bussed Electrical Center (BEC) Page 6335 System Diagnosis P1580 - P1584: Testing and Inspection For diagnosis of code P1582 refer to NOTE 21: NOTE 21: See DTC description and causes. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 875 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2875 5. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Disconnect the heater hoses at the floorpan bracket. 6. Support the rear axle with a jack stand. 7. Remove the track bar bolt. 8. Disconnect the LH rear wheel speed sensor electrical connector. 9. Remove the bolts and the two remaining line brackets. 10. Tilt the auxiliary heater outlet and inlet lines to drain any remaining coolant and remove the auxiliary heater outlet and inlet lines. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only, if needed. Page 9138 Page 698 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P0455 P0455 - P0459: Testing and Inspection P0455 For diagnosis of code P0455 refer to the system experiencing the problem. Computers and Control Systems P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8905 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 6864 View 151-27 Electrical - Wiring Harness Replacement Guidelines Wiring Harness: All Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Page 7151 Special Tool(s) Locations View 151-2 Page 9747 1. Remove the screws and remove the RH corner lamp. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Windshield Washer Reservoir Installation Note 1. Position the windshield washer reservoir filler neck through the inner frame support. Item 2: Windshield Washer Hoses Installation Note 1. Connect the windshield washer hoses to the windshield washer reservoir before installation. Page 8574 View 151-17 Locations View 151-6 Page 708 P0730 - P0734: Testing and Inspection P0734 For diagnosis of code P0734 refer to chart Part 4 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 7703 Seat Belt Tension Sensor: Description and Operation Air Bag and Safety Belt Pretensioner SRS SAFETY BELT TENSION SENSOR The safety belt tension sensor: is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a three-wire Hall-effect sensor that is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is used by the OCS system to identify the presence of a child safety seat on the front outboard passenger seat. The safety belt tension sensor senses the tension on the safety belt assembly then provides an output to the OCS system electronic control unit (ECU), indicating that the safety belt assembly is cinched. After sensing the weight applied to the seat by the occupant and using the safety belt tension sensor input, the OCS system determines how the occupant should be classified and communicates this information to the restraints control module (RCM). If the occupant is classified to be a child, the RCM will then automatically deactivate the passenger air bag module and passenger safety belt pretensioner. Page 7362 Special Tool(s) Page 3988 Page 5743 Brake Pad: Specifications Brake Pads Brake pad minimum thickness ........................................................................................................................................................... 3.0 mm (0.118 inch) Brake pad maximum thickness variation (pad-to-pad) ...................................................................................................................... 2.0 mm (0.079 inch) Brake pad maximum taper wear (in any direction) ............................................................................................................................ 3.0 mm (0.118 inch) Page 8290 Power Sliding Door Motor: Service Precautions CAUTION: Do not operate the PSD drive assembly actuator with the cables disconnected or damage to the drive assembly actuator may occur. Page 4321 Page 147 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Brakes - Rear Caliper Leaks (Mexico Vehicles Only) Brake Caliper: All Technical Service Bulletins Brakes - Rear Caliper Leaks (Mexico Vehicles Only) TSB 06-14-11 07/24/06 REAR BRAKE CALIPER LEAKS (VEHICLES SOLD IN MEXICO ONLY) - SERVICE TIP FORD: 2004-2006 Freestar MERCURY: 2004-2006 Monterey ISSUE 2004-2006 Freestar / Monterey vehicles may exhibit rear brake caliper fluid leaks - Service Tip. ACTION The rear brake caliper fluid leaks could be fluid seepage that may occur under certain conditions. Wetness around the piston seal is acceptable and should merely be wiped clean without any required repairs. SERVICE PROCEDURE If fluid accumulates enough that it causes dripping, then replace the brake caliper with the part that has been recently updated in service. Refer to Workshop Manual, Section 206-04, Rear Disc Brake. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 1109 07 Disclaimer Page 5599 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Main Climate Control Hose/Line HVAC: Description and Operation Main Climate Control REFRIGERANT LINES NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The compressor manifold and tube assembly is attached to the A/C compressor, is sealed with O-ring seals, and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas and a fitting used to mount a serviceable high-pressure A/C charge port valve. - The downstream side also contains a fitting used to mount the A/C pressure transducer. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure transducer can be removed without discharging the A/C system. Adjustable Pedal Switch View 151-8 Service and Repair Horn Switch: Service and Repair HORN SWITCH REMOVAL 1. Remove the driver air bag module 2. Remove the parts in the order indicated in the illustration and table. Item 3: Horn Switch Spring Removal Note 1. The 4 horn switch springs are not attached. To avoid losing the springs use caution when removing the horn switch. INSTALLATION 1. To install, reverse the removal procedure. Page 7774 Special Tool(s) Locations View 151-6 Page 8340 or repair surface as necessary. 5. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 to dry. 6. If reinstalling the original liftgate window glass, remove any excess urethane adhesive. 7. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. If installing a new liftgate window glass, apply urethane glass prep twice around the glass surface to be prepped. 8. If installing a new liftgate window glass, apply urethane glass prep to the same area that was prepped in the previous step. Allow 5 minutes to 10 minutes to dry. 9. If equipped, install Norton Foam Sealant 565 Black Foam Tape to the pinch weld area. 10. Cut the urethane adhesive applicator tip to specification. 11. Apply a bead of urethane adhesive to the liftgate door glass on the primed area. 12. CAUTION: Open the windows to prevent the rear window glass from being pushed out by air pressure if a door is closed. Install the liftgate window glass. After the glass is set, check for water leaks and add urethane adhesive where needed. 13. Install the rear wiper motor. Page 4235 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Locations Blower Motor Switch: Locations View 151-8 Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Page 3937 Page 5215 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... .................................................................. MERCON Page 4148 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Connector Views Engine Control Module: Connector Views Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Locations Page 1271 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P1702 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 9388 Page 4375 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 9335 92-2 Page 1431 P2100 - P2104: Testing and Inspection P2101 For diagnosis of code P2101 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9629 Locations View 151-5 Page 7839 Page 7447 Seat Occupant Sensor: Vehicle Damage Warnings CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Make sure the seat is completely assembled before rezeroing. Page 4454 Page 4256 Front Heater Core: Service and Repair Front HEATER CORE - FRONT REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Clamp off and disconnect the heater hoses from the heater core. 2. Lower the glove compartment. Page 885 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9720 Windshield Washer Switch: Testing and Inspection Page 8965 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Turn the ignition key to the ON position. 3. Locate the compass module at the base of the mirror. 4. Insert a paperclip into the small hole on the bottom of the sensor module. Press and hold until ZONE and the current zone setting (1-15) appear in the instrument cluster display, and release. 5. Press on the paperclip repeatedly to cycle through the possible zone settings until the setting for your geographic location is displayed. 6. Release pressure on the paperclip to exit the zone setting mode. After approximately 5 seconds the display will report the direction and the zone will be set. Engine Controls, A/T - Various Driveability Issues/DTC's Cowl: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 3127 Note: The bussed electrical center is located in the engine compartment. P0060 P0060 - P0064: Testing and Inspection P0060 For diagnosis of code P0060 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4935 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. P0010 P0010 - P0014: Testing and Inspection P0010 For diagnosis of code P0010 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 454 P0355 - P0359: Testing and Inspection P0358 For diagnosis of code P0358 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2883 Hose/Line HVAC: Description and Operation Auxiliary Climate Control UNDERBODY AUXILIARY A/C LINES NOTE: An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan spring lock coupling connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve. This filter must be inspected before a new thermostatic expansion valve is installed. The underbody auxiliary A/C lines carry refrigerant to the auxiliary A/C evaporator inlet, and away from the auxiliary A/C evaporator outlet. The auxiliary underbody lines have the following characteristics: The front auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the condenser to evaporator line to the tube-in-tube type auxiliary evaporator line. - The front auxiliary A/C evaporator outlet line carries refrigerant vapor from the tube-in-tube type auxiliary evaporator line to the front evaporator outlet line. - The tube-in-tube type auxiliary evaporator line combines a high-pressure tube and a low-pressure tube into a single assembly. The high-pressure tube is located inside of, and is separate from the low-pressure tube. - Four short jumper lines connect the tube-in-tube auxiliary evaporator line to the auxiliary evaporator inlet and outlet. The jumper lines are connected at the floorpan bracket. Page 746 P0750 - P0754: Testing and Inspection P0753 Torqshift For diagnosis of code P0753 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Page 4137 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 5544 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer A/T - Erratic Fluid Level Readings/Filler Tube Leaks Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T - Erratic Fluid Level Readings/Filler Tube Leaks TSB 06-18-13 09/18/06 ERRATIC FLUID LEVEL READING ON TRANSAXLE DIPSTICK - LEAKS - 4F50N, AX4N, AX4S FORD: 2000-2007 Taurus 2000-2007 Windstar 2004-2007 Freestar MERCURY: 2000-2005 Sable 2004-2007 Monterey This article supersedes TSB 05-14-5 to update the Service Procedure and vehicle model years. ISSUE Some 2000-2007 Taurus, 2000-2005 Sable, 2000-2003 Windstar, and 2004-2007 Freestar/Monterey vehicles, equipped with a 4F50N, AX4N, or AX4S transaxle, may exhibit an erratic fluid level reading on the transaxle dipstick and possible leaks around the filler tube and grommet. The condition may be due to a restricted transaxle vent. ACTION Repair the transaxle vent restriction by replacing the transaxle vent with a 90° vent stem, small hose clamp, two (2) tie raps, and 24" (61 cm) of 5/16" (8 mm) vacuum hose. The 5/16" (8 mm) vacuum hose will be routed from the 90° vent on the transaxle back to the cowl area, next to the brake master cylinder and tie rapped in place with the end of the hose facing down. Refer to the following Service Procedures. NOTE ON WINDSTAR, FREESTAR AND MONTEREY SEAL THE COWL PANEL GRILLE (COWL TO VENT PANEL) AREA, SEE TSB 06-14-10. NOTE LEAKS MAY BE MISDIAGNOSED AS COMING FROM THE PAN GASKET. ALWAYS FOLLOW WORKSHOP MANUAL, SECTION 307-01 TO LOCATE THE SOURCE OF A LEAK, AND LEAK CHECK WITH BLACK LIGHT AND DYE. SERVICE PROCEDURE 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Disconnect the crankcase vent tube(s) from the air cleaner outlet pipe. 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body. 4. Release the air cleaner housing clamp(s). 5. Separate the air cleaner cover from the air cleaner tray. 6. Windstar, Freestar and Monterey only: Remove cowl panel grille by following the procedure in TSB 06-14-10. 7. Disconnect the shift cable if located over the top of the vent. 8. Remove the vent, pull straight up on the vent with locking pliers, or carefully pry the vent from the transaxle case. 9. Install the replacement 90° vent stem. Page 4350 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) P1265 P1265 - P1269: Testing and Inspection P1265 OBD II - Base Gasoline For diagnosis of code P1265 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6417 Page 4291 Locations View 151-10 Page 2251 Locations View 151-6 Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 2633 4. WARNING: Do not separate components. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): - select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 7780 Page 909 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4543 Page 2616 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustration(s) and table(s). Item 1: Recliner Handle Cover Removal Note Page 1138 Inspection Page 5496 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Electrical - ABS/TCS/Park Brake Lamps Flickering ABS Light: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 3108 Page 6229 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 1795 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Page 7760 Impact Sensor: Description and Operation IMPACT SENSORS WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The RCM incorporates integral sensors that are not separately serviceable. All vehicles will have a front impact severity sensor located behind the front radiator grille under the hood latch assembly. There are two side impact sensors located under the front seats beneath the carpet. In addition there are two side impact sensors mounted near the driver and passenger C-pillars when the vehicle is equipped with driver and passenger safety canopy modules/seat side air bags. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all impact sensors. Page 7190 Page 9274 Hazard Warning Switch: Diagrams Page 2303 View 151-10 Page 9010 View 151-19 Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Page 8085 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. Page 7213 Cabin Temperature Sensor / Switch: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL In-Vehicle Temperature Sensor The in-vehicle temperature sensor operates in the following manner: - A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger compartment. - An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. - The aspirator hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor. - The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor. Page 5675 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Page 6567 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. Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment to the vehicle that affects the suspension system. Ride Height Specifications Compression Check: Specifications Part 1 0f 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 9320 Symbols Part 2 Page 6062 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 9558 Test W12 Normal Operation The trailer tow relays are supplied power from the BEC. Ground for the trailer tow parking lamp relay is provided through circuit 576 (DG). Ground for the trailer tow LH turn lamp relay is provided through circuit 374 (DB/WH). Ground for the trailer tow RH turn lamp relay is provided through circuit 378 (BN/YE). Ground for the trailer tow relay coils is controlled by the SJB. When the trailer tow parking lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 962 (BN/WH). When the trailer tow LH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 52 (YE). When the trailer tow RH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 64 (DG). Ground is supplied to the trailer through circuit 206 (WH). Possible Causes - circuit 52 (YE) open - circuit 64 (DG) open - circuit 206 (WH) open - circuit 374 (DB/WH) open or short to power - circuit 378 (BN/YE) open or short to power - circuit 576 (DG) open or short to power - circuit 962 (BN/WH) open - trailer tow relay - trailer - BEC - SJB Test X PINPOINT TEST X: THE TRAILER LAMPS ARE ON CONTINUOUSLY Test X1-X2 Page 2862 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Page 7432 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Second Row, RH SIDE IMPACT SENSOR - SECOND ROW, RH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system Page 9504 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 254 Inspection Page 7046 P0771 P0770 - P0774: Testing and Inspection P0771 For diagnosis of code P0771 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5779 Page 146 P0135 - P0139: Testing and Inspection P0138 For diagnosis of code P0138 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft pulley bolt .......................................................................................................................... ................................................. 160 Nm (118 ft. lbs.) Page 6525 Page 7409 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 8719 View 151-21 Page 2615 Part 1 Page 5005 Page 1790 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 5287 Page 7954 Page 6383 Page 2283 View 151-19 Page 9154 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 4716 127-2 Page 5024 3. If removing the ignition coil, remove the wiper motor and pivot assembly. 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Page 6574 6. Prepare the shock tower and alignment plate surfaces. ^ Remove any burrs. ^ Clean and paint any exposed metal. 7. Position the alignment plate. Loosely install the nuts. 8. Adjust the camber and caster. 9. Tighten the nuts. 10. Check the alignment settings. Follow the manufacturer's instructions. Readjust the camber and caster as necessary. Page 2376 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 8683 Seat Heater: Connector Views Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 1367 P1780 - P1784: Testing and Inspection P1781 For diagnosis of code P1781 refer to system being tested: Transmission Control If there is no link in the chart then: This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Engine Control Page 4917 Fuel Temperature Sensor: Description and Operation ENGINE FUEL TEMPERATURE SENSOR Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 3776 Locations View 151-5 Power Seat Motor Assembly, Right Page 1257 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Electronic Manual Temperature Control Blower Motor Switch: Description and Operation Electronic Manual Temperature Control BLOWER MOTOR SWITCH The blower motor switch is mounted in the climate control assembly and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF. Page 7711 Seat Belt Tensioner: Service Precautions WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an accidental deployment. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the safety belt pretensioner is deployed, hearing protection is required. - Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. Page 4366 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 8273 Power Sliding Door Module: Diagrams RH Side Page 8152 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 P1788 P1785 - P1789: Testing and Inspection P1788 For diagnosis of code P1788 refer to chart P0740-P1789 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 4707 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 Page 2420 View 151-5 Page 2835 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two 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 percent of the highest reading. Page 5484 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 7465 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustrations and tables. Item 1: Recliner Handle Cover Removal Note Page 9040 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 8701 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Passenger Side Page 9002 Special Tool(s) Page 8977 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Page 9213 Test F6 Normal Operation The stoplamp switch is supplied voltage from the SJB through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to circuit 810 (LG/RD) back to the SJB. Circuit 810 (LG/RD) is then routed out of the SJB to the brake shift interlock solenoid.The SJB monitors voltage input from the stoplamp switch. When the SJB senses brake pedal application, the SJB the sends voltage to the stoplamps. Possible Causes - circuit 10 (LG/RD) open - circuit 810 (LG/RD) open - stoplamp switch - SJB Test G PINPOINT TEST G: ONE OR MORE STOPLAMPS ARE INOPERATIVE Test G1 Page 197 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6634 Part 3 Of 3 5. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. 7. Fill and leak test the system. Item 1: Lower Reservoir Isolator Bolt Removal Note 1. Loosen the bolt and detach the reservoir from the isolators. Item 2, 3, 5, 13, 17, 21, 23, 25 and 27: Power Steering Line Removal Note 1. It may be necessary to disconnect the power steering lines to remove the individual components. Page 1824 View 151-4 Service and Repair Door Sensor/Switch (For Alarm): Service and Repair DOOR DISARM SWITCH - DRIVER DOOR REMOVAL 1. Remove the driver door trim panel. 2. Position the watershield aside. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Driver Door Disarm Switch Installation Note 1. The driver door disarm switch mark must be positioned towards the harness side of the switch prior to installation. Page 9586 Page 5977 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Page 112 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3082 Page 5703 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. Page 666 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Bussed Electrical Center (BEC) Fuse: Locations Bussed Electrical Center (BEC) Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Technician Safety Information Seat Cushion: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 1935 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 2367 Page 3654 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Specifications Idle Speed: Specifications Idle Speed is Computer Controlled Hot Idle ................................................................................................................................................ .............................................................. 700-730 rpm Locations View 151-11 Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Diagrams Page 719 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0741 refer to chart Part 3 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 1048 P1270 - P1274: Testing and Inspection P1272 OBD II - Base Gasoline For diagnosis of code P1272 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5417 Drive/Propeller Shafts, Bearings and Joints: Symptom Related Diagnostic Procedures Symptom Chart Symptom Chart P1400 P1400 - P1404: Testing and Inspection P1400 For diagnosis of code P1400 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 560 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2699 Trailer Tow Relay, Right Turn Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 2935 Page 9419 Page 9314 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 3557 Page 7612 Child Seat Tether Attachment: Description and Operation CHILD SAFETY SEAT TETHER ANCHORS WARNING: The child safety seat tether anchor/bolt MUST be securely tightened to specification. Otherwise, the child safety seat may not be correctly secured and the child could be injured if the vehicle is involved in a collision or stops suddenly. Child safety seat tether anchors (part of the lower anchors and tethers for children (LATCH) assembly) are located in the rear, second row seats at two seating positions and third row seats at three seating positions. If a child safety seat was in use during a collision, inspect the tether anchor, seat frame and seat backrest frame for damage. Install a new tether anchor, seat frame or seat backrest frame if necessary. For information on child safety seat tether anchors and lower anchors and tethers for children (LATCH) on vehicles equipped with second row bucket seats, refer to Child Safety Seat Tether Anchor Bucket Seat, Second Row. On vehicles with a second row bench seat, the child safety seat tether anchors and lower anchors and tethers for children (LATCH) system is a structural member of the seat frame. On vehicles a with third row bench seat, the child safety seat tether anchors and lower anchors and tethers for children (LATCH) system is a structural member of the seat backrest frame. For information on child safety seat tether anchors and lower anchors and tethers for children (LATCH) system on vehicles equipped with second and third row bench, refer to the appropriate procedure in Seats. ATTACHING SAFETY SEATS WITH TETHER STRAPS Some manufacturers make child safety seats that include a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as an accessory. Contact the manufacturer of the child safety seat for information about ordering a tether strap. For information, refer to Child Safety Seat Tether Anchor Bucket Seat, Second Row in the removal and installation portion or the owner's literature for usage information. LOWER ANCHORS AND TETHERS FOR CHILDREN (LATCH) The lower anchors and tethers for children (LATCH) system is a standardized and uniform attachment system for installing child safety seats in passenger vehicles. LATCH equipped child safety seats have two lower attachments that connect to the vehicle portion of the LATCH system. The vehicle portion of the system consists of two attachment points (6 mm wires), either part of the seat backrest, seat frame or bolted to the seat riser at five seating positions. It also incorporates the child safety seat tether anchors. The attachment points protrude from the biteline between the seat cushion and seat backrest. If a child safety seat was in use during a collision, inspect the vehicle portion of the system for damage. If any of the attachment points (6 mm wires) are damaged, a new one must be installed. See the appropriate removal and installation procedure. For vehicles equipped with second row bucket seats, refer to Child Safety Seat Tether Anchor Bucket Seat, Second Row. For vehicles equipped with second and third row bench, refer to Seats. Page 1107 Inspection Page 1803 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 5545 View 151-14 Locations View 151-6 Page 8717 View 151-15 Specifications Water Pump Torque Sequence Description and Operation Differential Assembly: Description and Operation Driveline System The drivetrain's power is generated by the engine and delivered to the transmission. The halfshafts transfer the engine torque from the transmission to the drive wheels. The front halfshafts have the following characteristics. ^ Halfshaft assemblies are not repairable and must be replaced if worn or damaged. ^ Inboard and outboard CV joints are connected to a splined shaft. Driveshaft bearing retainer circlips retain the CV joints to the splined shafts. ^ On the RH side, a driveshaft bearing retainer circlip retains the splined inboard CV Joint to the differential side gear. Install a new circlip every time the halfshaft is separated from the differential side gear. ^ A front axle wheel hub retainer secures the splined outboard CV joint to the wheel hub. ^ The lube-for-life CV joints use special CV joint grease. They require no periodic lubrication. CAUTION: Never pick up or hold the halfshaft only by the inboard or outboard CV joint. Handle all halfshaft components carefully during removal and installation. ^ Do not over-angle the CV joints. ^ Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing. ^ Never use a hammer to remove or install the halfshafts. ^ Do not allow the boots to contact sharp edges or hot exhaust components. ^ Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. ^ Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. ^ Do not drop the assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. ^ Do not remove the outer CV Joint by pulling on the interconnecting shaft. ^ Inspect all machined surfaces and splines for damage. ^ Never raise the vehicle using the halfshafts as lift points. ^ Never tow a vehicle using the halfshaft as anchor points for tow truck cable or chains. ^ Protect the boots from undercoating and rustproofing materials. Foreign materials on the boots will cause extreme advanced wear. Page 2024 Door Position Switch: Diagrams Sliding Door Contact Switch, Left Page 6196 Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Diagrams Clockspring Assembly / Spiral Cable: Diagrams Page 8339 2. Disconnect the two rear window defrost electrical connectors. 3. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. CAUTION: Care must be taken to avoid scratching the pinch weld. 4. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting. Using the special tool, cut the adhesive away from the liftgate window glass and remove the liftgate window glass. 5. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Liftgate Window Glass Installation Note CAUTION: After installing the new urethane-installed liftgate window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. 1. Dry-fit the liftgate window glass by centering it side-to-side and by adjusting the setting blocks (if equipped ) to get the correct position top and bottom. Use tape or non-permanent marking pencil to make alignment marks on the glass and the vehicle body. 2. After alignment, remove the rear window glass and molding assemblies from the vehicle and place them on a stable work surface. CAUTION: Care must be taken to avoid scratching the pinch weld. 3. Trim the remaining urethane adhesive on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld. 4. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean Specifications Brake Master Cylinder: Specifications Brake master cylinder nuts .................................................................................................................. ..................................................... 25 Nm (18 ft. lbs.) Brake master cylinder pressure switch ...................................................................................................................................................... 17 Nm (13 ft. lbs.) Brake master cylinder reservoir pin ........................................................................................................................................................ 8 Nm (71 inch lbs.) Page 2610 Seat Occupant Sensor: Vehicle Damage Warnings CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Make sure the seat is completely assembled before rezeroing. Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Page 103 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 282 P0205 - P0209: Testing and Inspection P0207 OBD II - Base Gasoline For diagnosis of code P0207 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8533 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Auxiliary Blower Motor Resistor Assembly View 151-27 Page 6685 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 9744 Windshield Washer Pump: Vehicle Damage Warnings CAUTION: Do not make any electrical connections prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Page 7082 Heater Core: Service and Repair Auxiliary HEATER CORE - AUXILIARY REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the LH quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. Item 5: Heater Hose Clamps Removal Note 1. NOTE: Position the heater core tubes over a suitable drain pan to prevent coolant from spilling into the vehicle. Clamp off and disconnect the heater hoses from the heater core. INSTALLATION 1. To install, reverse the removal procedure. 2. Fill the engine cooling system. Page 1309 P1715 - P1719: Testing and Inspection P1718 4R70W For diagnosis of code P1718 refer to chart Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7075 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Page 9677 3. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Rivet Removal Note 1. Connect the window control switch. 2. Connect the battery. Page 6614 Part 1 Of 3 Part 2 Of 3 Page 6680 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. P0155 P0155 - P0159: Testing and Inspection P0155 For diagnosis of code P0155 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1669 Page 7489 Side Air Bag: Service and Repair SIDE AIR BAG MODULE Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live side air bag module with the air bag and tear seam pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live side air bag module down on the cover tear seam. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Seat side air bag modules with damaged covers must be replaced. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - If a seat side air bag deployment took place a new seat back pad, trim cover, and side air bag module must be installed. Install a new seat back frame if necessary. - When installing a new seat side air bag module after deployment, refer to Seats for additional information concerning the installation of a new side air bag. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The driver seat is shown, the passenger seat is similar. Page 7352 Air Bag Control Module: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Page 9591 Turn Signal Switch: Diagrams Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 2652 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 7424 Impact Sensor: Description and Operation IMPACT SENSORS WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The RCM incorporates integral sensors that are not separately serviceable. All vehicles will have a front impact severity sensor located behind the front radiator grille under the hood latch assembly. There are two side impact sensors located under the front seats beneath the carpet. In addition there are two side impact sensors mounted near the driver and passenger C-pillars when the vehicle is equipped with driver and passenger safety canopy modules/seat side air bags. The RCM is mounted on the center tunnel under the instrument panel. Mounting orientation is critical for correct operation of all impact sensors. Page 8161 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 44 P0055 - P0059: Testing and Inspection P0059 For diagnosis of code P0059 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Front Blower Motor Resistor: Service and Repair Front BLOWER MOTOR RESISTOR - FRONT REMOVAL 1. Lower the glove compartment. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 841 P0970 - P0974: Testing and Inspection P0973 For diagnosis of code P0973 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service and Repair Sliding Door Handle: Service and Repair SLIDING DOOR HANDLES Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Right side shown, left side similar. 1. Remove the sliding door trim panel. P0710 P0710 - P0714: Testing and Inspection P0710 For diagnosis of code P0710 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 247 Inspection Page 2136 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Page 7584 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Description and Operation Keyless Entry Transmitter: Description and Operation Remote Keyless Entry (RKE) External Antenna The SJB utilizes an external coaxial antenna to receive remote transmitter signals. Remote Transmitter The remote transmitter will: lock or unlock all vehicle doors and liftgate without a key. - unlock/open a RH power sliding door and/or LH power sliding door (if equipped). - activate the perimeter alarm. - arm and disarm the perimeter anti-theft system (if equipped). The remote transmitter has a minimum operating range of 10 m (33 feet). Remote Transmitter Lock/Unlock Control - Unlock The remote transmitter provides unlock functions independently of key position, vehicle speed, or transmission position. The remote transmitter provides a 2-step process for unlocking the doors. Upon receipt of the first request for unlocking the doors, the remote transmitter requests the SJB to unlock the driver door only and activate perimeter lighting (if equipped). If another unlock request is received within 3 seconds of the first, the remote transmitter requests that both front doors, sliding doors and liftgate be unlocked. Remote Transmitter Lock/Unlock Control - Lock The remote transmitter provides lock functions independently of key position, vehicle speed or transmission position. The remote transmitter requests that all the doors be locked when the remote transmitter LOCK button is pressed. When the LOCK button is pressed once all doors lock. If the LOCK button is pressed again within 3 seconds of the first, the horn will chirp to confirm all doors (and hood, if equipped with alarm) are locked and closed. If any door, liftgate, or hood (with perimeter alarm) is ajar when the second lock request is received, 2 chirps will be heard. Remote Transmitter - Driver/Passenger Power Sliding Door Open/Close The remote transmitter feature provides open and close functionality for power sliding doors when the transmission is in PARK and the speed is less than 5 km/h (3 mph). Pressing the power sliding door button on the remote transmitter twice within 3 seconds opens the door. With the power sliding door open, pressing the power sliding door button twice within 3 seconds closes the door. Panic Alarm The panic alarm feature provides audible and visual alarms which are evident from the exterior of the vehicle. Activation of the panic alarm is accomplished by pressing the PANIC button on a remote transmitter whenever the key is in the OFF position. The SJB requests that the turn signals are flashed and horn sounds until the PANIC button is pressed again, 2 minutes and 45 seconds has elapsed since the time of activation, or the key is cycled to the ON position. Perimeter Lighting The perimeter lighting feature illuminates the exterior of the vehicle while the user approaches and enters the vehicle to provide better visibility to the user. Side Air Curtain Module, Driver View 151-13 Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 7805 Part 3 Part 4 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS Page 376 P0280 - P0284: Testing and Inspection P0282 For diagnosis of code P0282 refer to chart B1219-B1317 / P0182-P1272 Page 8211 1. Disconnect the exterior door handle actuating rod. 2. If equipped, disconnect the door lock cylinder rod. Item 11: Rivet Removal Note 1. Remove the rivets. INSTALLATION 1. To install, reverse the removal procedure. Item 11: Rivet Installation Note 1. Using the special tool, install the new rivets. Page 8433 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Service and Repair Sliding Door Window Glass: Service and Repair SLIDING DOOR WINDOW GLASS Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. Page 355 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5809 Brake Bleeding: Service and Repair Brake System Bleeding Special Tool(s) Manual WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Connect the diagnostic tool cable adapter into the vehicle Data Link Connector (DLC) under the dash and follow the scan tool instructions. 2. Clean all the dirt from the area and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 3. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Have an assistant hold firm pressure on the brake pedal. Page 1611 Page 105 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9161 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Specifications Fluid Pump: Specifications Pump assembly-to-main control .............................................................................. 10 Nm (89 inch lbs.)Pump cover-to-pump body 10 Nm (89 inch lbs.) Pump body-to-chain cover ............................... ..................................................................................................................................... 10 Nm (89 inch lbs.) EPC and TCC-to-pump body ............................................................................................... ....................................................................... 12 Nm (9 ft. lbs.) Separator plate-to-pump body and valve body ........................................................................................................................................... 11 Nm (8 ft. lbs.) System Diagnosis P2010 - P2014: Testing and Inspection For diagnosis of code P2014 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: Recalls Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Trailer Tow Relay, Right Turn Page 9654 Page 2157 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Locations View 151-2 Page 4705 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 Page 1363 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Engine Control P1641-P2106 If there is no link in the chart then: Page 4736 Disclaimer Locations Page 6575 11. CAUTION: Do not drill deeper than 9.6 mm (0.37 inch) into the shock tower. Drill three 3.2 mm (0.12 inch) holes through the alignment plate and shock tower. ^ Clean and paint any exposed metal. 12. Install three pop rivets. ^ Use 3.2 mm (0.12 inch) diameter x 6.4 mm (0.25 inch) grip range steel pop rivets. 13. Install the cowl top vent panel. Page 1620 Page 8842 Page 6210 Page 4978 Variable Induction Control Actuator: Service and Repair INTAKE MANIFOLD RUNNER CONTROL (IMRC) ACTUATOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Item 3: IMRC Actuator Rods Installation Note 1. New plastic actuator rod retainers must be installed any time the IMRC rods are disconnected. Item 5: IMRC Actuator Installation Note 1. Before installing the IMRC actuator, be sure to rotate the driver motor plate until the levers make contact with the set screws, then rotate the motor until the motor bracket bolt holes are aligned with the holes in the lower intake manifold. Page 2863 13. Install the special tool between the fuel supply line and the fuel supply manifold. Side Air Bag Module, Right Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: All Technical Service Bulletins Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 9047 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Seat Adjust Switch, Driver Side Front View 151-16 Page 8164 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. P1537 P1535 - P1539: Testing and Inspection P1537 For diagnosis of code P1537 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1588 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 239 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0192 refer to chart Locations View 151-13 Page 1021 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1503 P2275 - P2279: Testing and Inspection P2278 For diagnosis of code P2278 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1548 Power Seat Control Module: Diagrams Page 9061 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 1189 Inspection Page 5945 Electronic Brake Control Module: Diagrams Page 1311 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8334 2. Disconnect the two rear window defrost electrical connectors. 3. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. CAUTION: Care must be taken to avoid scratching the pinch weld. 4. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting. Using the special tool, cut the adhesive away from the liftgate window glass and remove the liftgate window glass. 5. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Liftgate Window Glass Installation Note CAUTION: After installing the new urethane-installed liftgate window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. 1. Dry-fit the liftgate window glass by centering it side-to-side and by adjusting the setting blocks (if equipped ) to get the correct position top and bottom. Use tape or non-permanent marking pencil to make alignment marks on the glass and the vehicle body. 2. After alignment, remove the rear window glass and molding assemblies from the vehicle and place them on a stable work surface. CAUTION: Care must be taken to avoid scratching the pinch weld. 3. Trim the remaining urethane adhesive on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld. 4. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean Page 7382 Clockspring Assembly / Spiral Cable: Description and Operation CLOCKSPRING The clockspring: is mounted on the steering column, behind the steering wheel. - provides a continuous electrical path from the restraints control module (RCM) to the driver air bag module. - the turn signal cancel-cam is part of the clockspring assembly. Page 7458 system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. 4. CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Customer Safety Information Seat Belt: Customer Safety Information WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the belt is fitted snugly and as low as possible around the hips, not the waist. Failure to follow these precautions could increase the chance and severity of injury in a collision. Page 7550 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) is mounted on the center tunnel under the instrument panel. The RCM carries out the following functions: supplies current flow to the inflators to deploy the air bags in the event of a deployable crash. - supplies current flow to the inflators to deploy the safety canopies in the event of a deployable crash. - activates the safety belt retractor pretensioners to remove slack from the safety belt. - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the lamp fault code (LFC) detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). - signals the instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. - contains an internal safing sensor which is not serviced separately. - records deployment event data. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the LFC. The air bag indicator will flash the LFC three times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the (DLC), using a scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient current to deploy the front air bags and safety belt pretensioners in the event that the ignition circuit is damaged or lost in a collision before the RCM determines that air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Page 7295 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 7592 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 144 P0135 - P0139: Testing and Inspection P0136 For diagnosis of code P0136 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4828 4. If removing the fuel tank or fuel pump module, use the special tool and siphon the fuel through the fuel filler hose into a suitable container. Part 1 Climate Controlled Seat Module, Driver Side View 151-16 Page 5984 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Page 1744 System Diagnosis P0340 - P0344: Testing and Inspection For diagnosis of code P0340 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0141 P0140 - P0144: Testing and Inspection P0141 For diagnosis of code P0141 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9619 Heated Glass Element Relay: Testing and Inspection Page 6056 Alternator: Service and Repair GENERATOR REMOVAL NOTE: The 3.9L engine is shown, the 4.2L engine is similar. 1. Disconnect the battery. 2. Release the accessory drive belt tension and position the belt aside. 3. Remove the parts in the order indicated in the illustration and table. Item 3: Generator B+ Cable Nut Removal Note Page 2870 Heater Hose: Description and Operation UNDERBODY HEATER LINES The underbody auxiliary heater lines have the following features: - The underbody auxiliary heater inlet line is a aluminum tube assembly that carries coolant from the engine coolant supply line to the auxiliary heater core inlet. - The underbody auxiliary heater outlet line carries coolant from the auxiliary heater core to the front heater core outlet line. Connector Views Wiper Motor: Connector Views Page 1972 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Page 2385 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8013 Bussed Electrical Center (BEC) Fuse Block: Application and ID Bussed Electrical Center (BEC) Page 1697 Page 7385 Part 1 Page 213 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5752 FSA VIN LIST ACTIVATED? Yes Available through the website. Owner names and addresses were available by September 27, 2004. NOTE: 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 action. 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 owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer 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 Field Service Action. 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. 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. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S24 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid .............................................................................................................................. .......................................... 11.6 Liters (12.25 quarts) Page 5611 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 2017 View 151-13 Page 7490 - A seat with climate control and manual lumbar is shown, all others are similar. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the seat on the side with the affected side air bag module. Service Precautions Evaporative Canister Filter: Service Precautions WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. Page 2096 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling Pinpoint Test. NOTE: Refer to Multimeter User's Manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, install a new switch; otherwise, return to the calling Pinpoint Test. Page 5116 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Restraint System - SRS Lamp ON/DTC B1342 Set Impact Sensor: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 6212 Page 7537 Page 4701 Symbols Part 3 Page 1556 Page 3015 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Electrical - ABS/TCS/Park Brake Lamps Flickering ABS Light: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 7374 Part 3 3. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustrations and tables. Item 5: Quarter Trim Panel (RH) Removal Note 1. Separate the quarter trim panel enough to remove the D-pillar trim panel. Item 14: Quarter Trim Panel (LH) Removal Note 1. Separate the quarter trim panel enough to remove the D-pillar trim panel. Item 22: Headliner Removal Note 1. Separate the headliner from the roof, at the rear hatch area, to expose the bridge resistor. - If equipped with third row seating, pull down to release the retainers and remove the safety belt retractor cover. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Page 3761 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a message on the vehicle communication network (SCP or HS-CAN). The key features of the PCM-VSO system are to: - Infer vehicle movement from the output shaft sensor signal - Convert transmission output shaft rotational information to vehicle speed information - Compensate for tire size and axle ratio with a programmed calibration variable - Utilize a transfer case sensor for four wheel drive applications - Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer data message via the vehicle communication network data link. The VSO hard -wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22 Hz per MPH (1.3808 Hz per 1 km/h). Page 7276 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Page 6692 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. Page 2887 Hose/Line HVAC: Service and Repair Auxiliary Evaporator Outlet and Inlet Line AUXILIARY EVAPORATOR OUTLET AND INLET LINE REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Disconnect the front auxiliary outlet and inlet line fittings. 1 Disconnect the fittings. 2 Remove the nuts and the line bracket. Discard the O-ring seals. 4. Remove the three bolts and position the shield aside. 5. Disconnect the fittings at the front tube-in-tube fitting. - Discard the O-ring seals. Bussed Electrical Center (BEC) Fuse Block: Application and ID Bussed Electrical Center (BEC) Page 7816 1. Remove the OCS. - Feed the OCS components (hose, transducer, wire harness, electronic control unit (ECU) and connectors) through the seat cushion pan opening. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. Part 1 Page 3078 Page 7469 Part 2 1. CAUTION: - While positioning the seat cushion pan and occupant classification sensor assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. Page 707 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations Page 6660 Page 346 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2977 Refrigerant: Fluid Type Specifications R-134a Refrigerant YN-19(USA).......................................................................................................... .......................................................WSH-M17B19-A R-134a Refrigerant CYN-16-R(Canada)............ ..........................................................................................................................................WSH-M17B 19-A Traction Control - Short Duration Activation Steering Angle Sensor: Customer Interest Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Auxiliary Relay Box Page 8856 Page 1217 Inspection Page 8123 Test W10-W11 Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 3931 Page 2724 Electrical - Wiring Harness Replacement Guidelines Wiring Harness: All Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 9777 Electrical - ABS/TCS/Park Brake Lamps Flickering Wiring Harness: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). A/C - Compressor Leaking/Inoperative Compressor Shaft Seal: Customer Interest A/C - Compressor Leaking/Inoperative TSB 06-4-9 03/06/06 A/C COMPRESSOR NOT OPERATIONAL / LOW FREON-SHAFT SEAL LEAKS FORD: 2003 Escort 2003-2006 Focus, Mustang, Taurus 2003 Explorer Sport, Windstar 2003-2005 Excursion, Explorer Sport Trac 2003-2006 Escape, F-150, F-Super Duty, Ranger 2004-2006 Freestar 2006 Low Cab Forward LINCOLN: 2002 Blackwood 2006 Mark LT MERCURY: 2003-2005 Sable 2004-2006 Monterey 2005-2006 Mariner ISSUE Some 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal. ACTION Replace the A/C compressor shaft seal following the Service Procedure. SERVICE PROCEDURE If the shaft seal on the front of the A/C compressor is leaking, replace the shaft seal (F1VY-19D665-A) and not the compressor assembly. Replacing the shaft seal should correct the leaking condition. When replacing the seal, follow the procedure outlined in Workshop Manual, Section 412-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060409 Use Standard Labor Actual Operation For Compressor Time Removal And Installation If Available, And Claim Additional Labor Required As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19D665 42 Page 9189 Symbols Part 4 Page 9391 92-2 Page 4922 Specifications Axle Nut: Specifications Note: Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut Axle nut ................................................................................................................................................ ................................................... 130 Nm (96 ft.lbs.) Page 9289 Page 3056 Note: The bussed electrical center is located in the engine compartment. Page 788 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1621 Page 6034 Torque Specifications Page 6495 Page 2778 Item 7: Air Cleaner Cover Installation Note 1. NOTE: No tools are needed to install the air cleaner cover. Installation should be carried out using hands only. Use the alignment notches to correctly align the air cleaner cover to the air cleaner tray. P1157 P1155 - P1159: Testing and Inspection P1157 For diagnosis of code P1157 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations Page 8388 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 9700 3. Remove the parts in the order indicated in the illustration and table. To remove individual components, only carry out the listed steps. 4. To install, reverse the removal procedure. Item 1: Rivet Removal Note 1. Connect the window control switch. 2. Connect the battery. Power Window Switch, RH Side Front View 151-19 Page 9048 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 706 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0733 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3755 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Trailer Tow Relay, Right Turn Page 5017 Ignition Coil: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 7306 Page 6282 Page 5694 Symbols Part 4 P1385 P1385 - P1389: Testing and Inspection P1385 For diagnosis of code P1385 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4006 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5218 7. CAUTION: When plugging the cooler tube fitting, make sure the plug is made of a soft material to prevent damage to the internal seal of the cooler tube fitting. Insert a plug into the cooler tube fitting on the transaxle. 8. CAUTION: When the steady stream of transmission fluid stops flowing, the engine must be turned off to prevent damage to the transaxle. Engine rpm should not exceed curb idle speed while draining the transmission fluid. Start the engine and run at idle while observing the flexible hose for 40-60 seconds until the steady stream of fluid stops flowing. Turn the engine off. This step will drain approximately 1.9 - 2.8 liters (2 - 3 quarts) of transmission fluid. 9. Fill the transaxle with 9.5 liters (10 quarts) of clean automatic transmission fluid. 10. CAUTION: When the steady stream of transmission fluid stops flowing, the engine must be turned off to prevent damage to the transaxle. Engine rpm should not exceed curb idle speed while draining the transmission fluid. Start the engine and run at idle while observing the flexible hose for 2-3 minutes until the steady stream of fluid stops flowing. Turn the engine off. This step will drain approximately 9.5 liters (10 quarts). Page 8432 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Page 2932 On some of the affected vehicles, the power steering lines may not be fully engaged into the quick connect fittings, at the rack and pinion gear assembly. See Figure 1. This procedure involves verifying that both lines are fully engaged at the rack and pinion steering gear assembly. SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. NOTE: This bolt must be removed to ensure proper engagement of the power steering return line (low-pressure line) into the quick connect fitting during Step 3. Remove the 8 mm bolt securing the power steering return line (low-pressure line) to the subframe crossmember. See Figure 2. 3. Inspect and verify both power steering line connections at the quick connect fittings as follows: NOTE: When checking the lines, be sure to aggressively push and pull on the lines. This is necessary due to the amount of force needed to disengage the line from the fitting. Page 6867 Air Door Actuator / Motor: Locations View 151-9 Page 6556 Technician Safety Information Seat Occupant Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes at the beginning of the removal procedure. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - Do not separate components. Page 4517 1. Using the special tool, remove the HO2S and the catalyst monitor sensors. INSTALLATION 1. To install, reverse the removal procedure. Item 2: HO2S and Catalyst Monitor Sensors Installation Note 1. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S and the catalyst monitor sensors. Using the special tool, install the HO2S and the catalyst monitor sensors. Page 8917 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone lamp installed into the vehicle instrument panel in a position visible to each front seat occupant. The restraints control module (RCM) controls the state of the PAD indicator through a direct hard-wire connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is ON to indicate the passenger air bag module is deactivated (OFF). Some exemptions to this are made in certain scenarios such as when the front passenger seat is determined to be empty, and therefore indication of a deactivated passenger air bag module is not necessary. In all cases the PAD indicator is OFF when the passenger air bag module is activated (ON). When the ignition switch is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front occupants proper functional operation of the PAD indicator. The PAD indicator will illuminate/not illuminate within 1.0 + 0.5 seconds of a change of state from the OCS system. When an OCS system fault is present the SRS defaults the passenger air bag module to ON (activated) regardless of the size of the occupant in the front outboard passenger seat. The PAD indicator will be OFF. Passenger Air Bag And PAD Indicator Status The table indicate the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant. Page 3409 2. Remove the catalyst monitor sensor electrical connector mounting bracket. Item 13: Engine Front Cover Cap Screw Removal Note 1. CAUTION: The cap screw is hidden by the oil filter housing. Failure to remove this retainer will result in damage to the engine front cover. Remove the engine front cover cap screw. Items 14-15: Engine Front Cover and Stud Removal Note 1. NOTE: Mark the studs so they can be reinstalled in their original location. Loosen the engine front cover studs and remove them with the engine front cover. Items 17-23: Timing Components Removal Note 1. Remove the synchronizer drive gear. 1. Remove the bolt. 2. Remove the synchronizer drive gear. Locations View 151-18 Page 323 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection General Procedures Heater Hose: Service and Repair General Procedures HEATER HOSE COUPLING Special Tool(s) SPECIAL TOOL(S) DISCONNECT CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. 1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Depressurize the engine cooling system. 2. Push the heater hose toward the tube to fully expose the locking tabs. 3. NOTE: - When compressing the white coupling retainer with the special tool, the special tool must be perpendicular to and on the highest point of the coupling. - If the heater hose coupling is accessible, the retainer tabs can be compressed by hand to disconnect the heater hose. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. Page 4219 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer P2126 P2125 - P2129: Testing and Inspection P2126 For diagnosis of code P2126 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7991 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) REMOVAL 1. CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery. 2. Remove the driver seat. 3. Remove the parts in the order indicated in the illustration and table. Page 5062 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 8920 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Page 199 P0170 - P0174: Testing and Inspection P0172 OBD II - Base Gasoline For diagnosis of code P0172 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 741 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0750 refer to chart Part 5 Page 7870 Page 7493 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. Separate the side air bag module electrical connector and wire harness pin-type retainers from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. NOTE: Due to seat options, some components, connectors and harnesses may or may not be present. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. NOTE: Due to seat options, some components, connectors and harnesses may or may not be present. If equipped, disconnect the seat cushion heated seat element. Item 22: Backrest Trim Cover Removal Note 1. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced (cleaning is permissible). Release the seat back trim cover lower J-clips. Page 6366 Page 9372 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 6162 Page 1262 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2843 Drive Belt: Service and Repair Accessory Drive Belt, Tensioner and Pulley 1. With the vehicle in neutral, position it on a hoist. 2. Remove the parts in the order indicated in the illustration and table. Part 1 0f 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Accessory Drive Belt Removal Note Page 7054 Evaporator Core: Testing and Inspection EVAPORATOR/CONDENSER CORE - ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. 2. Disconnect the suspect evaporator core or condenser core from the A/C system. 3. Clean the manifold fittings. 4. Connect the appropriate test fittings from the A/C Fittings Set to the condenser or evaporator core tube connections. 5. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter that will activate the valve. The test is not valid if the shut-off valve does not open. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45-minuteevacuation is necessary to remove any refrigerant from oil left in the evaporator core or condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new evaporator core or condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. 9. If the evaporator core or condenser core does leak, as verified by the above procedure, install a new evaporator core or condenser core. Page 5131 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Page 7090 1. Remove the five screws and the floor duct. 2. Remove the seven screws and the heater core cover. - Detach the wire harness. 3. Remove the heater core. Item 17: Evaporator Core Removal Note 1. Remove the eleven screws and the evaporator core cover. 2. Remove the dash panel seal and the evaporator core. Item 18: Air Inlet Duct Removal Note 1. Remove the air inlet duct. 1 Disconnect the air inlet mode door actuator electrical connector. 2 Remove the four screws and the air inlet duct. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Fill the engine coolant level. 4. Evacuate, leak test and charge the refrigerant system. Page 8151 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear P0261 P0260 - P0264: Testing and Inspection P0261 For diagnosis of code P0261 refer to chart B1219-B1317 / P0182-P1272 Page 4977 Variable Induction Control Actuator: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) Intake Manifold Tuning Valve (IMTV) The intake manifold tuning valve (IMTV) (Figure 109) 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 will not be energized below approximately 2600 rpm or higher on some vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There must be a positive change in voltage from the TP sensor along with the increase in rpm to open the shutter. 2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Page 212 P0175 - P0179: Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0175 refer to chart P0107-P0193 Page 1510 P2700 - P2704: Testing and Inspection P2701 For diagnosis of code P2701 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1139 P1435 - P1439: Testing and Inspection P1437 For diagnosis of code P1437 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Liftgate Ajar Switch Page 2641 Page 2113 Page 9549 DTC Index B1342 - B2070 Locations View 151-6 Page 2309 Page 1277 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6414 Traction Control - Short Duration Activation Steering Angle Sensor: Customer Interest Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Service and Repair Fan Clutch: Service and Repair REMOVAL AND INSTALLATION Radiator, Cooling Fan and Shroud Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the transmission fluid cooler. Part 1 Of 2 Page 3653 Page 7265 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 562 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7125 Refrigerant: Fluid Type Specifications R-134a Refrigerant YN-19(USA).......................................................................................................... .......................................................WSH-M17B19-A R-134a Refrigerant CYN-16-R(Canada)............ ..........................................................................................................................................WSH-M17B 19-A Page 8242 Recall 04V446000: Front Hub/Rotor/Bearing Replacement Power Steering Line/Hose: All Technical Service Bulletins Steering - Power Steering Hose Leak in Extreme Cold TSB 07-1-2 01/22/07 POWER STEERING HOSE LEAK NEAR COOLER - EXTREME COLD CLIMATE AREAS ONLY -4 °F (-20 °C) AND COLDER FORD: 2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey ISSUE Some 2004-2007 Freestar, Monterey and 2003 Windstar vehicles may exhibit a leak at the power steering hose return line. This concern will exist in extreme cold climate, -4 °F (-20 °C) and colder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS IS ONLY FOR VEHICLES USED IN NORTHERN U.S. AND CANADA WITH TEMPERATURES REACHING -4 °F (-20 °C) AND COLDER. IT IS UNNECESSARY TO FLUSH SYSTEMS WITH SYNTHETIC MERCON(R) MULTI-PURPOSE AUTOMATIC TRANSMISSION FLUID IN CLIMATES ABOVE THIS TEMPERATURE. 1. Remove the power steering fluid reservoir cap. 2. Replace power steering return line. 3. When installing the return line, it is necessary to also install an additional worm clamp right after power steering return line hose clamp. (Figure 1) 4. Flush the factory installed power steering fluid per Workshop Manual, Section 211-00 (Power Steering System Flushing). 5. Replace fluid with Synthetic MERCON(R) Multi-Purpose Automatic Transmission Fluid. NOTE DO NOT REUSE THE POWER STEERING FLUID THAT HAS BEEN FLUSHED FROM THE POWER STEERING SYSTEM. NOTE DO TO COLD FLUID EFFICIENCIES, DO NOT MIX FLUID TYPES. NOTE Page 3114 Page 9530 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 5577 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Initial Inspection and Diagnostic Overview Battery: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the cause is not visually evident, proceed to the pinpoint test. See: Pinpoint Tests Page 602 P0600 - P0604: Testing and Inspection P0603 OBD II - Base Gasoline For diagnosis of code P0603 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle Page 828 P0960 - P0964: Testing and Inspection P0962 4R70W For diagnosis of code P0962 refer to chart Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle Page 1971 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Page 5999 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Removal and Installation 1. Raise and support the vehicle. NOTE: Clean the area around the sensor hole prior to removal. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 3: Wheel Speed Sensor Installation Note 1. Lube the O-ring before installing a new wheel speed sensor. Locations Page 4169 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 442 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Brake Booster Sensor View 151-3 Connector Views Alternator: Connector Views Page 4261 Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: 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 VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, 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 L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. For Ford L-M technician's, check out the "Programmable Module Installation" link on the Professional Technician Society (PTS) web sight for quick Programmable Module data information by vehicle when using WDS or NGS. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need 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. Page 6491 Page 3194 10. Using special tool 205-343 (T95T-3514-A), secure the 2 inner bellows clamps. 11. Reinstall the steering gear per Section 211-00 of the Workshop Manual. 12. Perform a front wheel alignment. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050908A 2004-2005 2.5 Hrs. Freestar/Monterey Replace One Halfshaft, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) 050908B 2004-2005 2.8 Hrs. Freestar/Monterey Replace Both Halfshafts, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) DEALER CODING CONDITION BASIC PART NO. CODE 3B436 01 Disclaimer System Diagnosis P1290 - P1294: Testing and Inspection For diagnosis of code P1290 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Driver Memory Seat Horizontal Sensor Page 3348 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 5. To install, reverse the removal procedure. 6. Fill the engine with clean engine oil. Item 1: Drain Plug And Gasket Removal Note 1. Allow the engine oil to drain. Item 7: Oil Pan Removal Note 1. Clean the oil pan mating surfaces with metal surface cleaner. Items 8-6: Oil Pan Installation Note Page 9542 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 Page 8912 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 9041 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 1861 Page 7408 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 3426 2. Rotate the crankshaft until the timing marks and keyways align. 3. Compress and install a retaining pin to hold the timing chain tensioner. 4. Remove the camshaft gear, crankshaft gear and the timing chain as an assembly. 5. Remove the bolts and the timing chain tensioner. Items 23-17: Timing Components Installation Note Page 3031 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 37 P0050 - P0054: Testing and Inspection P0054 For diagnosis of code P0054 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9381 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 Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Trailer Tow Relay, Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 3424 4. Using the special tool, remove the crankshaft pulley. 5. Raise the subframe into position, then install the bolts. Item 9: Crankshaft Front Seal Removal Note 1. Using the special tool, remove the front crankshaft front seal. Item 11: Engine Front Cover Stud Bolt Removal Note 1. Disconnect the catalyst monitor sensor electrical connector. Page 5353 10. Using special tool 205-343 (T95T-3514-A), secure the 2 inner bellows clamps. 11. Reinstall the steering gear per Section 211-00 of the Workshop Manual. 12. Perform a front wheel alignment. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050908A 2004-2005 2.5 Hrs. Freestar/Monterey Replace One Halfshaft, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) 050908B 2004-2005 2.8 Hrs. Freestar/Monterey Replace Both Halfshafts, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) DEALER CODING CONDITION BASIC PART NO. CODE 3B436 01 Disclaimer Page 4234 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Main Light Switch View 151-8 Page 8162 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 Page 8029 Page 1196 Inspection Page 7141 Refrigerant Identifier With Air-Radicator Page 7455 1. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit or installing a new seat cushion trim cover, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 22: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 24: Occupant Classification Sensor (OCS) Removal Note 1. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. Page 7288 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 4307 View 151-5 Page 8718 View 151-20 Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Without Auxiliary Climate Control ........................................................................................................ ........................................................ 10 oz (296 ml) With Auxiliary Climate Control ............................................................................................................. ........................................................ 12 oz (355 ml) ABS - Module Replacement Service Tip Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 8848 Brake Switch (Cruise Control): Description and Operation Brake Pressure Applied/Brake Deactivator Switch BRAKE PRESSURE APPLIED/BRAKE DEACTIVATOR SWITCH The brake pressure applied (BPA) switch also sometimes called the brake deactivator switch for vehicle speed control deactivation. Is a normally closed switch, which supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is depressed, the normally closed switch will open and power is removed from the PCM. On some applications the normally closed BPA switch along with the normally open brake pedal position (BPP) switch are used for a brake rationality test within the PCM. The PCM misfire monitor profile learn function can be disable if a brake switch failure occurs. If one or both brake pedal inputs to the PCM did not change states when they were expected to a diagnostic trouble code P1572 can be set by the PCM strategy. Page 6659 View 151-9 Steering - Power Steering Hose Leak in Extreme Cold Power Steering Line/Hose: All Technical Service Bulletins Steering - Power Steering Hose Leak in Extreme Cold TSB 07-1-2 01/22/07 POWER STEERING HOSE LEAK NEAR COOLER - EXTREME COLD CLIMATE AREAS ONLY -4 °F (-20 °C) AND COLDER FORD: 2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey ISSUE Some 2004-2007 Freestar, Monterey and 2003 Windstar vehicles may exhibit a leak at the power steering hose return line. This concern will exist in extreme cold climate, -4 °F (-20 °C) and colder. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE THIS IS ONLY FOR VEHICLES USED IN NORTHERN U.S. AND CANADA WITH TEMPERATURES REACHING -4 °F (-20 °C) AND COLDER. IT IS UNNECESSARY TO FLUSH SYSTEMS WITH SYNTHETIC MERCON(R) MULTI-PURPOSE AUTOMATIC TRANSMISSION FLUID IN CLIMATES ABOVE THIS TEMPERATURE. 1. Remove the power steering fluid reservoir cap. 2. Replace power steering return line. 3. When installing the return line, it is necessary to also install an additional worm clamp right after power steering return line hose clamp. (Figure 1) 4. Flush the factory installed power steering fluid per Workshop Manual, Section 211-00 (Power Steering System Flushing). 5. Replace fluid with Synthetic MERCON(R) Multi-Purpose Automatic Transmission Fluid. NOTE DO NOT REUSE THE POWER STEERING FLUID THAT HAS BEEN FLUSHED FROM THE POWER STEERING SYSTEM. NOTE DO TO COLD FLUID EFFICIENCIES, DO NOT MIX FLUID TYPES. NOTE Service and Repair Lateral Accelerometer: Service and Repair Accelerometer Removal and Installation NOTE: When installing a new accelerometer, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. 1. Remove the driver side front seat. 2. Remove the lower B-pillar trim panel. 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: Electrical Connector Removal Note 1. Fold back the carpeting flap to gain access to the accelerometer. Page 6254 Locations View 151-13 Page 8098 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 1077 P1285 - P1289: Testing and Inspection P1288 For diagnosis of code P1288 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 5449 Page 4670 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Page 4735 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 9020 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center display is a green vacuum fluorescent, fixed format display. The message center display is integral to the instrument cluster. The message center is controlled by the 3 message center switches (INFO, SETUP and RESET). PRINCIPLES OF OPERATION Message Center The message center is an integral part of the instrument cluster. The message center communicates with the PCM, SJB, and ABS/TC/stability assist module over the SCP network. Display Information The display modes are: information - setup - system check - warning - temporary alert The message center information can be selected by pressing any of the following buttons: SELECT - RESET - ENGLISH/METRIC The select display and the reset display will time-out and default to the information display mode. The temporary alert display will interrupt the current display to show the status of an event that has just happened. The warning display interrupts the current display until cleared or reset by the driver. Information Displays The information displays are as follows: odometer mileage - distance to empty - trip odometer - average fuel economy - trip elapsed drive time - upper 2 lines off, lower line on Setup Displays The setup displays are timed modes and default back to the information display function. The setup display modes are: - language - English/metric units - system check System Check The system check display is a sub-routine of the setup menu. They are timed modes that terminate after a finite interval, then default back to the information display function. The system check display modes are: oil life XXX% (configurable) - charging system - washer fluid level - brake fluid level - door ajar - exterior lamp status - traction control - low tire pressure - fuel level - miles to empty Warning Messages The warning messages can interrupt the display until cleared or reset by the driver. The warning messages are single cycle, non-resettable and repetitive warning messages. The single cycle warning messages will display once whenever the key is turned to ON or a fault occurs in a system and can be cleared by pressing the RESET button. Once cleared, the messages are not displayed again until the next ignition cycle except CHECK TIRES and TURN SIGNAL ON, both of which are displayed again if a fault condition re-occurs. The single cycle warning messages are: Page 2028 Door Position Switch: Diagrams Page 2331 Page 2907 On some of the affected vehicles, the power steering lines may not be fully engaged into the quick connect fittings, at the rack and pinion gear assembly. See Figure 1. This procedure involves verifying that both lines are fully engaged at the rack and pinion steering gear assembly. SERVICE PROCEDURE 1. Raise the vehicle on a hoist. 2. NOTE: This bolt must be removed to ensure proper engagement of the power steering return line (low-pressure line) into the quick connect fitting during Step 3. Remove the 8 mm bolt securing the power steering return line (low-pressure line) to the subframe crossmember. See Figure 2. 3. Inspect and verify both power steering line connections at the quick connect fittings as follows: NOTE: When checking the lines, be sure to aggressively push and pull on the lines. This is necessary due to the amount of force needed to disengage the line from the fitting. Page 2159 View 151-29 Page 5324 3. CAUTION: Do not use the bolts to draw pump assembly and main control valve body onto the chain cover case. Component damage may occur. Install the pump assembly and main control valve body. Using the special tools, loosely install the bolts. 4. Remove the special tools and install the two bolts in their place. Tighten all the bolts in the sequence shown. 5. Install the transaxle wire harness and retaining clip into the separator plate. Page 4524 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 2056 Page 2009 Door Position Switch: Locations Sliding Door Contact Switch, Left View 151-15 Page 225 Inspection Brake Pedal Position Switch View 151-11 Page 8335 or repair surface as necessary. 5. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow 6 to 10 to dry. 6. If reinstalling the original liftgate window glass, remove any excess urethane adhesive. 7. CAUTION: Wipe off the urethane glass prep immediately after each application because it flash dries. Apply deliberate strokes, making sure not to overlap the applied area. If installing a new liftgate window glass, apply urethane glass prep twice around the glass surface to be prepped. 8. If installing a new liftgate window glass, apply urethane glass prep to the same area that was prepped in the previous step. Allow 5 minutes to 10 minutes to dry. 9. If equipped, install Norton Foam Sealant 565 Black Foam Tape to the pinch weld area. 10. Cut the urethane adhesive applicator tip to specification. 11. Apply a bead of urethane adhesive to the liftgate door glass on the primed area. 12. CAUTION: Open the windows to prevent the rear window glass from being pushed out by air pressure if a door is closed. Install the liftgate window glass. After the glass is set, check for water leaks and add urethane adhesive where needed. 13. Install the rear wiper motor. Page 6844 Item 10: Lower Arm (LH/RH) Removal Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. CAUTION: Do not use a prying device or separator fork between the lower arm ball joint and the knuckle. Damage to the ball joint or ball joint dust boot can result. Only use the pry bar by inserting it into the lower control arm body opening. NOTE: To aid access to lower control arm, turn wheel end to right lock when removing the left lower control arm and turn wheel to the left lock when removing the right lower control arm. NOTE: Do not use air tools to remove the lower arm. After separating the lower control arm from the wheel knuckle, immediately install the special tool over ball stud before releasing lower control arm and knuckle into rest positions. ^ Leave the special tool in place during service and only remove prior to reassembly. 2. Using a large pry bar (for leverage), insert into opening in the lower control arm. ^ Approach the lower control arm from the rear of the vehicle to avoid any contact with brake lines. ^ The larger the pry bar, the easier it will be to separate the LCA from the knuckle. ^ Do not pry in the ball Joint to knuckle Joint. Doing so may cause damage to the ball Joint boot. Item 11: Wheel Stud Removal Note 1. Using a suitable press, remove the wheel stud from the wheel hub and bearing assembly. Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE SENSOR A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 1 A/C Evaporator Temperature (ACET) Sensor Voltage And Resistance Chart, Part 2 The air conditioning evaporative temperature (ACET) sensor senses evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance affects the voltage drop across the sensor terminals. As A/C evaporator air temperature changes, the varying resistance of the ACET sensor changes the voltage the PCM detects. The ACET sensor is used to more accurately control A/C clutch cycling, improving defrost/demist performance, reduce A/C clutch cycling, etc. Page 6933 Blower Motor Resistor: Service and Repair Auxiliary BLOWER MOTOR RESISTOR - AUXILIARY REMOVAL 1. Remove the LH quarter trim panel. 2. Remove the auxiliary blower motor resistor. 1 Disconnect the auxiliary blower motor resistor electrical connector. 2 Remove the screws. 3 Remove the auxiliary blower motor resistor. INSTALLATION 1. To install, reverse the removal procedure. Bussed Electrical Center (BEC) Fuse: Locations Bussed Electrical Center (BEC) Electrical - ABS/TCS/Park Brake Lamps Flickering Traction Control Indicator Lamp: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 3441 2. Remove the catalyst monitor sensor electrical connector mounting bracket. Item 13: Engine Front Cover Cap Screw Removal Note 1. CAUTION: The cap screw is hidden by the oil filter housing. Failure to remove this retainer will result in damage to the engine front cover. Remove the engine front cover cap screw. Items 14-15: Engine Front Cover and Stud Removal Note 1. NOTE: Mark the studs so they can be reinstalled in their original location. Loosen the engine front cover studs and remove them with the engine front cover. Items 17-23: Timing Components Removal Note 1. Remove the synchronizer drive gear. 1. Remove the bolt. 2. Remove the synchronizer drive gear. Page 4281 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL VALVE The idle air control (IAC) valve assembly controls 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. NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED. The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the internal diode is measured in crossed terminal position with a digital multimeter, there will be an incorrect or negative reading. It is important that the mating component and harness connectors are correctly oriented. Diagnostic procedures emphasize this importance. The PCM uses the IAC valve assembly to control: - No touch start - Cold engine test idle for rapid warm-up - Idle (corrects for engine load) - Stumble or stalling on deceleration (provides a dashpot function) - Over-temperature idle boost. Page 6201 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 7828 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The power seat track seat position sensor is mounted at the outboard front of the seat track. The manual seat track seat position sensor is mounted at the LH front of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. 2. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or Locations View 151-13 Page 1308 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7412 View 151-14 Locations View 151-14 Page 6217 Page 3474 13. Install the special tool between the fuel supply line and the fuel supply manifold. Page 1677 Page 9084 P0121 P0120 - P0124: Testing and Inspection P0121 For diagnosis of code P0121 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P1565 P1565 - P1569: Testing and Inspection P1565 For diagnosis of P1565 refer to chart DTC Index P0500 - P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6030 The purpose of the battery eye is to indicate the state of charge of the battery in the assembly plant and while on the dealership lot. The battery eye can also indicate the state-of-charge when the vehicle is delivered to the dealership and during the pre-delivery inspection process. The battery eye is made up of a viewing plate, two balls and a small passage. The balls indicate the specific gravity of the electrolyte by floating higher or lower in the passageway. It is important to note that the battery eye checks the specific gravity on only one battery cell. ^ RED usually indicates that the battery state-of-charge is at 40 percent or less ^ YELLOW indicates that the battery state-of-charge is between 40 and 57 percent ^ GREEN indicates that the battery state-of-charge is above 57 percent ^ NO COLOR/BLACK sometimes no color can be seen at all and the eye appears black. This could happen after the battery has been in service for several years and some of the plate material has coated the balls ^ CLEAR could happen if the battery case becomes damaged and the electrolyte has fallen below the plates The battery eye is a state-of-charge indicator, but should not be used to condemn a battery after the vehicle has been placed in service. After delivery, many things could happen to cause the battery eye to lead to misdiagnosis of the battery's actual state-of-charge. After the vehicle has been in service, the battery eye does not always accurately reflect the battery state-of-charge. The GR-1 190 Battery Tester/Charge or Micro 490 Digital Battery Analyzer should be used to determine battery condition. Do not replace a battery based solely on the indication given by the battery eye. The battery eye color simply indicates the battery state-of-charge, not its condition. If the eye indicates the battery may be discharged, Use GR-1 190 Battery Tester/Charger to determine the battery condition or recharge the battery before testing using the Micro 490. A red or yellow indicator usually means that the battery is discharged, not defective. Therefore, a battery with a red or yellow eye should not automatically be replaced. The indicator could remain red after recharge because the balls are stuck in the passageway. When new vehicles are delivered to the dealership, be sure to check the state-of-charge indicator within 72 hours. If the battery eye is red, charge the battery until it is fully charged. Refer to the following Battery Charging Procedure. Batteries discharge while the vehicle is on the lot due to normal parasitic key-off loads. Also, vehicles in inventory are generally driven short distances with heavy electrical loads. Over a period of time (30 days or more), vehicles still in inventory will have shallow to deeply discharged batteries. The vehicle's charging system is designed to supply the vehicle's electrical power needs and maintain the battery near full charge during normal vehicle use. The charging system is not capable of bringing a deeply discharged battery back near full charge in a short amount of time such as allowing the vehicle to idle for 15 minutes to "recharge the battery". Discharged batteries should be charged using an external charger. Refer to the following Battery Charging Procedure. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. Battery Charging Procedure Dealers with GR-1 190, use the Diagnostic Fast Charge Mode on GR-1 190 for this procedure and for dealers without a GR-1 190 the following procedure applies: The Micro 490 Digital Battery Analyzer (Rotunda Part Number 162-00004) is extremely accurate if used properly and can distinguish the difference between good, defective, worn out, or discharged-only batteries. This TSB provides proper battery charging procedures for batteries that are identified as "discharged-only". Discharged-only batteries can be recharged using the procedures in this TSB without reducing battery life or charge capacity. NOTE BATTERY CHARGERS HAVE IMPROVED GREATLY WITH THE ADDITION OF THE NEW GENERATION OF "PULSE CHARGERS". THESE NEW CHARGERS PULSE CURRENT INTO THE BATTERY THAT BREAKS DOWN THE SULFATION LAYER ON THE BATTERY PLATES AND GENERALLY REDUCE CHARGING TIMES TO LESS THAN 1 HOUR. ^ DEEPLY DISCHARGED - A battery that is drained over a prolonged period of time such as an unsold vehicle, to the point it is dead ^ SHALLOW DISCHARGE - A battery that is drained by leaving an accessory on for several hours or a few days, and has a very low charge Locations Page 4167 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 6025 Page 7722 Page 2307 Headlamp Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. Page 2753 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. Toe Positive Toe (Toe In) Negative Toe (Toe Out) The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding aftermarket equipment to the vehicle that affects the suspension system. Ride Height Page 9693 2. NOTE: Lubricate the existing adhesive with water to aid the special tool while cutting. Using the special tool, cut the adhesive from the sliding door window glass. 3. NOTE: - There are 4 locator pins on the sliding door window glass that hold the glass in place during assembly. - An assistant may be required to avoid damaging the door when the door glass comes loose. Using the special tool, distance the sliding door glass from the sliding door and discard the glass. 4. Remove the locator pins from the door skin and discard the pins. 1 Rock the pins back and forth applying pressure to remove the pins. 2 Rotate the pins 90 degrees left or right and remove the pin. 3 Using a suitable tool, cut the head off the pin and retrieve it from the bottom of the door. 5. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Sliding Door Window Glass Installation Note CAUTION: - A new sliding door window glass must be installed to prevent wind noise or water leaks. - After installing the new sliding door window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. Page 9201 Brake Lamp: 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. 90-1 Page 9291 Headlamp Switch: Testing and Inspection Page 2277 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Engine - Spark Knock on Light Load/Acceleration Variable Induction Control Actuator: Customer Interest Engine - Spark Knock on Light Load/Acceleration TSB 07-16-17 08/20/07 SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION - 3.8L, 3.9L, AND 4.2L - SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC) FORD: 2001-2004 Mustang 1996-2003 Windstar 1997-2003 E-150 1997-2008 F-150 2004-2007 Freestar MERCURY: 2004-2007 Monterey ISSUE Various vehicles equipped with a 3.8L, 3.9L or 4.2L engine and Split Port IMRC may exhibit spark knock under light load and acceleration. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect for disconnected IMRC actuator rods. 1. Check both right hand and left hand side IMRC rods are properly attached to the actuator motor and intake manifold runner. 2. If the IMRC actuator rods are found to be connected properly, do not continue with this TSB. Refer to Powertrain Control/Emission Diagnosis Manual. 3. If any IMRC actuator rods are disconnected, refer to Workshop Manual (WSM), Section 303-14 for IMRC service. 4. If any IMRC actuator rod linkages are found disconnected, replace all four (4) linkage rod retainers. (Figure 1) WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT071617 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 4039 Firing Order: Locations Page 772 P0765 - P0769: Testing and Inspection P0767 For diagnosis of code P0767 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 7047 4. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps. Item 10: Heater Hose Removal Note 1. Clamp off and disconnect the heater hoses at the heater core. Item 16: Heater Core Removal Note Page 3500 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 7384 auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. Make sure the road wheels are in the straight-ahead position. 4. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the steering wheel removal and installation procedure. Remove the steering wheel. Page 8511 Page 2762 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the straight-forward position by attaching a rigid link from the steering wheel to the seat. 3. Check the toe settings. Follow the manufacturer's instructions. 4. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. 6. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Page 348 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations Page 2581 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Second Row, LH SIDE IMPACT SENSOR - SECOND ROW, LH Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Page 6547 position the connectors so they point downward this will avoid the connector catching water in case of a water leak. Extra Open Connectors - Procedure For "Wet" Environment/Exterior Wiring Harness: 1. Cut each wire from the extra connector as close to the connector as possible (Figure 2). 2. Using dual wall heat shrink tubing, position tubing over each individual wire (Figure 3). 3. Use a shielded, flameless heat gun to heat the repair area until the tubing shrinks and adhesive flows out of both ends of the shrink tubing. While the adhesive is still hot, use pliers to pinch the ends of the heat shrink tubing closed to form a moisture proof seal (Figure 4). 4. Use electrical tape to bundle the wires together, then stow the bundle under an existing harness in the area. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Page 3746 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 8866 Service and Repair Valve Spring: Service and Repair Rocker Arms, Valve Springs, Push Rods, Valve Tappets Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location. 1. Remove the valve cover. 2. If removing the valve tappets, remove the lower intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 5691 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 9202 90-2 Page 6458 Page 4382 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 6554 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Page 3932 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 9412 Fog/Driving Lamp Relay: Testing and Inspection Page 533 P0460 - P0464: Testing and Inspection P0463 For diagnosis of code P0463 refer to chart P0463-P0503 NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: Page 8560 Page 3963 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 7956 - liftgate ajar - check left headlamp - check right headlamp - low brake fluid - check left turn lamps - check right turn lamps - check brake lamps - check left parking lamps - check right parking lamps - washer fluid low - check traction control - check fuel cap - change oil soon - oil change required - check tire - turn signal on The repetitive warning messages will display whenever the key is turned to ON or a fault occurs in a system. These can be cleared by pressing the RESET button. Repetitive warning messages will re-appear again after a 10-minute interval until the condition is corrected. The repetitive warning messages are: parking brake set - check brake system - reduced engine power - stop engine safely - transmission overheated The non-resettable warning messages display whenever the key is turned to ON and a fault occurs in a system. The fault must be corrected to clear the non-resettable warning messages. The non-resettable warning messages are: driver door ajar - passenger door ajar - driver rear door ajar - passenger rear door ajar Temporary Alert Messages The temporary alert display will interrupt the current display to show the status of an event that has just happened. The temporary alert messages are: traction control active General Specifications Drive/Propeller Shafts, Bearings and Joints: Specifications General Specifications General Specifications Part 1 Of 2 Part 2 Of 2 Page 3969 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 485 Inspection Page 2823 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 7981 Symptom Chart Page 8762 Page 1816 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 1270 P1700 - P1704: Testing and Inspection P1702 Torqshift For diagnosis of code P1702 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Page 1055 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1274 refer to chart Page 7079 Part 2 Description and Operation Air Injection Pump: Description and Operation ELECTRIC AIR PUMP Electric Air Pump The electric AIR pump (Figure 112) provides pressurized air to the Secondary Air Injection system. The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of system backpressure and system voltage. The inlet system of the AIR pump incorporates a splash cap which helps to guard against dirt and water. Page 9361 Marker Lamp: 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. 92-1 Page 7485 Page 8992 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 997 Inspection Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: Customer Interest Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Auxiliary Blower Motor Relay Page 6207 Page 1453 P2120 - P2124: Testing and Inspection P2122 For diagnosis of code P2122 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 183 Inspection Page 7183 Compressor Clutch Relay: Testing and Inspection Page 1080 Inspection Page 2958 7. CAUTION: When plugging the cooler tube fitting, make sure the plug is made of a soft material to prevent damage to the internal seal of the cooler tube fitting. Insert a plug into the cooler tube fitting on the transaxle. 8. CAUTION: When the steady stream of transmission fluid stops flowing, the engine must be turned off to prevent damage to the transaxle. Engine rpm should not exceed curb idle speed while draining the transmission fluid. Start the engine and run at idle while observing the flexible hose for 40-60 seconds until the steady stream of fluid stops flowing. Turn the engine off. This step will drain approximately 1.9 - 2.8 liters (2 - 3 quarts) of transmission fluid. 9. Fill the transaxle with 9.5 liters (10 quarts) of clean automatic transmission fluid. 10. CAUTION: When the steady stream of transmission fluid stops flowing, the engine must be turned off to prevent damage to the transaxle. Engine rpm should not exceed curb idle speed while draining the transmission fluid. Start the engine and run at idle while observing the flexible hose for 2-3 minutes until the steady stream of fluid stops flowing. Turn the engine off. This step will drain approximately 9.5 liters (10 quarts). Page 4408 Main Relay (Computer/Fuel System): Testing and Inspection Specifications Timing Cover: Specifications Timing Cover Torque Sequence Engine front Cover studs ......................................................................................................................................... ................................................. 7 Nm (62 inch lbs.) Cover Bolt no. 12 ................................................ .............................................................................................................................. 10 Nm (89 inch lbs.) All other fasteners ........................................................................................................................ ......................................................... 28 Nm (21 ft. lbs.) Page 6256 Page 9050 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. Page 5942 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 6997 Compressor Fitting HVAC: Service and Repair COMPRESSOR MANIFOLD AND TUBE ASSEMBLY REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Remove the parts in the order indicated in the illustration and table. Page 4129 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 6504 Note: The bussed electrical center is located in the engine compartment. Service and Repair Push Rod: Service and Repair Rocker Arms, Valve Springs, Push Rods, Valve Tappets Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location. 1. Remove the valve cover. 2. If removing the valve tappets, remove the lower intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 4028 Item 7: Air Cleaner Cover Installation Note 1. NOTE: No tools are needed to install the air cleaner cover. Installation should be carried out using hands only. Use the alignment notches to correctly align the air cleaner cover to the air cleaner tray. Page 8671 Symbols Part 3 Page 4109 View 151-5 Page 1330 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1744 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Multifunction Switch Headlamp Switch: Diagrams Multifunction Switch Page 6164 Page 6456 Relay Box: Diagrams Smart Junction Box (SJB) Page 500 Inspection Page 297 P0210 - P0214: Testing and Inspection P0212 For diagnosis of code P0212 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6521 Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2). Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed (Figure 2). Silicone must not be used. Excess wire from the harness can be folded back on itself to maintain the harness length. Reapply any convolute and tape that was removed to make the repair. For 16 AGW and Smaller Diameter Wire Forward Crash Sensor View 151-1 Locations Number One Cylinder: Locations Page 8677 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 Page 3388 Part 2 Of 2 1. Disconnect the RH front anti-lock brake wheel sensor electrical connector. 2. Position a safety stand under the RH side of the subframe. Trailer Tow Relay, Parking Lamp Page 5414 Drive/Propeller Shafts, Bearings and Joints: Description and Operation Driveline System The drivetrain's power is generated by the engine and delivered to the transmission. The halfshafts transfer the engine torque from the transmission to the drive wheels. The front halfshafts have the following characteristics. ^ Halfshaft assemblies are not repairable and must be replaced if worn or damaged. ^ Inboard and outboard CV joints are connected to a splined shaft. Driveshaft bearing retainer circlips retain the CV joints to the splined shafts. ^ On the RH side, a driveshaft bearing retainer circlip retains the splined inboard CV Joint to the differential side gear. Install a new circlip every time the halfshaft is separated from the differential side gear. ^ A front axle wheel hub retainer secures the splined outboard CV joint to the wheel hub. ^ The lube-for-life CV joints use special CV joint grease. They require no periodic lubrication. CAUTION: Never pick up or hold the halfshaft only by the inboard or outboard CV joint. Handle all halfshaft components carefully during removal and installation. ^ Do not over-angle the CV joints. ^ Damage will occur to an assembled inboard CV joint if it is over-plunged outward from the joint housing. ^ Never use a hammer to remove or install the halfshafts. ^ Do not allow the boots to contact sharp edges or hot exhaust components. ^ Never use the halfshaft assembly as a lever to position other components. Always support the free end of the halfshaft. ^ Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. ^ Do not drop the assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. ^ Do not remove the outer CV Joint by pulling on the interconnecting shaft. ^ Inspect all machined surfaces and splines for damage. ^ Never raise the vehicle using the halfshafts as lift points. ^ Never tow a vehicle using the halfshaft as anchor points for tow truck cable or chains. ^ Protect the boots from undercoating and rustproofing materials. Foreign materials on the boots will cause extreme advanced wear. Instruments - False Parking Aid Warnings Parking Assist Distance Sensor: All Technical Service Bulletins Instruments - False Parking Aid Warnings TSB 05-6-4 04/04/05 FALSE PARKING AID WARNINGS FORD: 2005 Five Hundred, Freestyle 2002-2003 Windstar 2002-2005 Excursion, Expedition, Explorer, F-Super Duty 2003-2005 Escape 2004-2005 F-150, Freestar LINCOLN: 2002 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 2005 Montego 2002-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 05-4-19 to update the description for labor operation F. ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This condition may also occur on vehicles equipped with the forward sensing system (FSS) when vehicle is in reverse or drive. ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before replacing any sensor(s). SERVICE PROCEDURE NOTE THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS. OPERATION AND COMMON CAUSE OF WARNINGS The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the FSS the system is operational when the vehicle is in reverse or drive. The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters) from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper. NOTE CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS COMPOSED OF. NOTE THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE EXCEPTION STATED IN THE NOTE ABOVE. NOTE THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT ADJUSTABLE. In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or give warnings for 3 seconds then ceases, the occurrence may be due to any of the following reasons: Locations Page 6049 Micro 490 Digital Battery Analyzer Page 8430 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Page 8935 Symbols Part 2 Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Page 9508 Symbols Part 3 Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 8937 Symbols Part 4 Page 3864 Page 6681 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 539 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagrams Page 7167 Page 6004 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Auxiliary Relay Box Page 3021 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Auxiliary Climate Control Control Assembly: Description and Operation Auxiliary Climate Control CONTROL ASSEMBLY The auxiliary climate control system has dual controls for the driver and rear passengers consisting of temperature/air distribution and blower speed. The front auxiliary climate controls are built into the dual-zone EMTC and EATC modules. The rear auxiliary climate control assembly is mounted in a separate overhead console positioned on the headliner above the second row seating area. Page 8550 Power Seat Control Module: Diagrams Page 1218 P1535 - P1539: Testing and Inspection P1538 For diagnosis of code P1538 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 5833 Page 4173 Symbols Part 3 Locations View 151-18 Locations View 151-11 Specifications Alignment Specifications Page 8126 Special Tool(s) Page 1804 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 253 P0195 - P0199: Testing and Inspection P0197 For diagnosis of code P0197 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2643 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. NOTE: The power seat track seat position sensor is mounted at the outboard front of the seat track. The manual seat track seat position sensor is mounted at the LH front of the seat track. Position the driver seat rearward enough so that upon removal the sensor can clear the bracket. 2. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or Page 7745 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 4702 Symbols Part 4 Page 8936 Symbols Part 3 Technician Safety Information Brake Switch (Cruise Control): Technician Safety Information WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. Page 6142 Page 7737 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 6160 Page 9060 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Page 3581 1. Disconnect the fluid cooler tubes from the connector assembly. ^ Push the fluid cooler tube inward slightly, squeeze the retaining clip, and with a slight twisting motion, pull the fluid cooler tube out of the connector assembly. Item 15: Radiator Support Bolts Removal Note 1. Detach the power steering lines from both sides of the radiator lower support. 2. Remove the bolt and position the A C muffler bracket aside. Item 19: Radiator Removal Note 1. Lower the vehicle, cut the mechanic's wire and remove the radiator, cooling fans and shroud as an assembly. Page 6652 Page 852 P0975 - P0979: Testing and Inspection P0977 For diagnosis of code P0977 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Service and Repair Front Steering Knuckle: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Page 7402 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 2384 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 4545 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 7613 Child Seat Tether Attachment: Service and Repair CHILD SAFETY SEAT TETHER ANCHOR - BUCKET SEAT, SECOND ROW REMOVAL WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters (if so equipped), child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. NOTE: For Lower Anchors and Tethers for Children (LATCH) on second row bench seat, refer to seat frame removal and installation in Seats. For Lower Anchors and Tethers for Children (LATCH) on third row bench seat, refer to seat backrest removal and installation in Seats. 1. To service the Lower Anchors and Tethers for Children (LATCH), remove the bucket seat from vehicle. 2. Remove the parts in the order indicated in the illustration and table. Page 6362 Page 2500 Fuel Temperature Sensor: Service and Repair FUEL PRESSURE AND TEMPERATURE SENSOR REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Release the fuel system pressure. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 1570 View 151-17 With Remote Audio Controls Cruise Control Switch: Service and Repair With Remote Audio Controls SPEED CONTROL SWITCH - WITH REMOTE AUDIO CONTROLS REMOVAL 1. Remove the air bag. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8234 3. Position the door window glass halfway down to gain access to the door window glass rivets. - Remove the rivets. Item 4: Rivet Removal Removal Note 1. Remove the rivets. Item 5: Front Door Window Regulator Removal Note 1. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Rivet Installation Note 1. Using the special tool, install the rivets. Item 1: Rivet Installation Note 1. Using the special tool, install the rivets. Page 5889 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 6141 Note: The bussed electrical center is located in the engine compartment. Page 98 P0115 - P0119: Testing and Inspection P0117 OBD II - Base Gasoline For diagnosis of code P0117 refer to chart P0112-P0147 If there is no link in the chart then: Page 9384 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Door Lock Actuator, Right Front View 151-19 Page 5246 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 2745 Wiper Switch: Testing and Inspection Description and Operation Seat Belt Reminder Lamp: Description and Operation SAFETY BELT WARNING SYSTEM - DRIVER SAFETY BELT The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to the ON position, the safety belt warning light illuminates for one to two minutes and the warning chime sounds for four to eight seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, the warning light and warning chime turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for four to eight seconds with no chime. BELT MINDER The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. The passenger safety belt minder feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed set point. To activate or deactivate the belt minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Page 734 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-14 Multifunction Switch Headlamp Switch: Diagrams Multifunction Switch Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Page 5508 View 151-13 Page 3460 Fuel Pressure Test Port: Description and Operation Natural Gas Fuel System SCHRADER/SERVICE VALVE schrader/service valve (if equipped) provides a service port to the low pressure fuel system. This valve is needed to relieve the pressure in the system before and during service. This valve could also be used to monitor the pressure near the injectors during diagnostic procedures. Page 7748 View 151-14 Page 5546 Electronic Brake Control Module: Diagrams Page 6253 Page 9200 Brake Lamp: Connector Views Page 9644 View 151-19 Page 5600 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Page 5301 Page 134 Inspection Page 8437 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 3040 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 9544 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. Page 4812 Fuel Rail: Vehicle Damage Warnings CAUTION: Do not apply battery positive voltage (B+) directly to the fuel injector electrical connector terminals. The solenoids may be damaged internally in a matter of seconds. CAUTION: 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. Page 2297 Headlamp Dimmer Switch: Testing and Inspection Page 7228 Solar Sensor: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Solar Radiation Sensor The solar radiation sensor supplies information to the EATC module indicating sunload. Page 7344 Air Bag Control Module: Vehicle Damage Warnings CAUTION: - Installing a J-nut in place of a weld nut is not a recommended repair. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. - Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. Page 8602 Page 6080 Starter Motor: Service and Repair STARTER MOTOR REMOVAL WARNING: When carrying out maintenance on the starting system be aware that the heavy gauge leads are connected directly to the battery. Make sure the protective caps are in place when maintenance is completed. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 1887 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 3448 Item 5: Oil Filter Installation Note 1. Tighten oil filter one half turn after gasket makes contact with oil filter housing. Page 99 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0117 refer to the Base Gasoline Diagnostic Chart: P0112-P0147 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 4073 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Auxiliary Relay Box P1780 P1780 - P1784: Testing and Inspection P1780 4R100 For diagnosis of code P1780 refer to system being tested: Transmission Control If there is no link in the chart then: This code is not a valid code for this vehicle Page 6938 Page 3366 Intake Manifold: Service and Repair Lower Intake Manifold Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the coolant bypass tube. 2. Remove the fuel injection supply manifold. Part 1 Of 2 Page 8950 44-2 Page 4423 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Page 1905 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 92 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 6896 Page 8180 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 7131 1. Verify that the valves on the deluxe injector loop kit are closed. 2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye. 3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves. 4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine. Start the engine. 5. Open the high-pressure service valve. 6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system. Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview Inspection and Verification 1. Verify the customer's concern by operating the engine to duplicate the condition. 2. Inspect to determine if any of the mechanical concerns apply: - All of the accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory. - If any of the accessories are damaged, have a worn or damaged bearing, or internal torsional resistance above normal, install a new component as required. - NOTE: If fluids get on the drive belt (including power steering fluid, engine coolant, engine oil or air conditioning system lubricant), clean the drive belt with soap and water and thoroughly rinse with clean water. A new drive belt does not have to be installed if no apparent damage has occurred. NOTE: If the drive belt tensioner arm does not rotate freely without binding, the drive belt tensioner is worn or damaged. If the drive belt is outside the installation wear range window, install a new drive belt. A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release tension to the drive belt. 3. Inspect for drive belt cracking/chunking/wear. Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. - has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. A new drive belt should be installed if chunking occurs. V-Ribbed Serpentine Drive Belt With Cracks Across Rim V-Ribbed Serpentine Drive Belt With Chunks of Rib Missing 4. If the concern(s) remains after inspection, determine the symptoms. See: Symptom Related Diagnostic Procedures Page 9485 Page 3523 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 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 such as the Compression Tester 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 five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Part 1 0f 2 Part 2 Of 2 Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Locations View 151-6 Page 586 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6593 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 1988 Page 8159 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 4358 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 2834 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 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 such as the Compression Tester 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 five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Part 1 0f 2 Part 2 Of 2 Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Locations View 151-10 Page 229 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection Ball Joint Inspection 1. Raise and support the vehicle. 2. Prior to carrying out any inspection of the ball joints, inspect the front wheel bearings for looseness. 3. While an assistant pulls and pushes the top and bottom of the tire, observe the relative movement between the ball Joint and the front suspension lower arm. Any movement at or exceeding the specification indicates a worn or damaged ball Joint. Install a new lower control arm as necessary. 4. While an assistant pulls and pushes the top and bottom of the tire, observe the relative movement between the ball Joint and the front suspension upper arm or rear suspension upper arm. Any movement at or exceeding the specification indicates a worn or damaged ball joint. Install a new front suspension upper arm or rear suspension upper arm as necessary. 5. Lower the vehicle. Page 2200 Oil Pressure Sender: Service and Repair CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the generator. 2. Remove the accessory drive belt idler pulley. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Items 3-5: Generator Mounting Bracket Removal Note 1. NOTE: Clearance between the engine and vehicle frame is limited. The A/C compressor mounting bracket brace, two long bolts, and generator mounting bracket should be removed from the engine as an assembly. Page 9079 Oil Pressure Sender: Service and Repair CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the generator. 2. Remove the accessory drive belt idler pulley. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. Items 3-5: Generator Mounting Bracket Removal Note 1. NOTE: Clearance between the engine and vehicle frame is limited. The A/C compressor mounting bracket brace, two long bolts, and generator mounting bracket should be removed from the engine as an assembly. Locations View 151-5 Page 3295 Valve Cover: Service and Repair Valve Cover LH CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. Remove the upper intake manifold. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Item 8: LH Valve Cover Gasket Removal Note 1. Do not discard the gasket. It may be reused if it is not damaged. Page 6124 Engine Cooling Fan Relay 1 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 1 Page 182 P0155 - P0159: Testing and Inspection P0156 For diagnosis of code P0156 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9543 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Parking Aid Sensor, Front, Outer Left Page 3390 Assemble the special tools, then place the crankshaft front seal onto the special tools. 3. Using the special tools, install the crankshaft front seal. Item 6: Crankshaft Pulley Installation Note 1. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley. Using the special tool, install the crankshaft pulley. Item 3: Subframe Bolt Installation Note 1. Raise the subframe into position, then install the bolts. 2. Connect the RH front anti-lock brake wheel sensor electrical connector. Page 4177 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 Locations View 151-5 Page 3044 Special Tool(s) Page 1191 Inspection System Diagnosis P0510 - P0514: Testing and Inspection For diagnosis of code P0511 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7257 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 2061 Multifunction Switch Headlamp Switch: Diagrams Multifunction Switch Page 3268 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Item 3: Subframe Bolt Removal Note Page 5321 14. Install the special tools. 15. Remove the upper main control cover bolts. 16. Remove the rear transaxle support insulator bolt, nut and support insulator. Page 2708 Page 498 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P0456 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6424 Page 5325 6. Connect the electrical connectors. 7. NOTE: The transaxle side cover gasket is reusable if not torn or ripped. Remove the gasket. Clean and inspect the gasket, reinstall into the pan. 8. NOTE: After the cover has been installed, it may be necessary to raise the subframe back into place if it had been lowered. Install the side cover, gasket and bolts. Page 5114 Page 702 P0730 - P0734: Testing and Inspection P0732 4R70W For diagnosis of code P0732 refer to chart Part 4 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 8412 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 1933 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 762 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-8 Locations View 151-6 Page 3608 Heater Core: Service and Repair Auxiliary HEATER CORE - AUXILIARY REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak tested before it is removed from the vehicle. 1. Remove the LH quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. Item 5: Heater Hose Clamps Removal Note 1. NOTE: Position the heater core tubes over a suitable drain pan to prevent coolant from spilling into the vehicle. Clamp off and disconnect the heater hoses from the heater core. INSTALLATION 1. To install, reverse the removal procedure. 2. Fill the engine cooling system. Page 5023 Ignition Coil: Service and Repair Customers have reported success using the following spark plug wire placement on the coil pack." IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Page 7317 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 5530 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 5101 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Steering Column Opening Cover Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Page 356 P0270 - P0274: Testing and Inspection P0271 For diagnosis of code P0271 refer to chart B1219-B1317 / P0182-P1272 Page 7250 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Page 8304 Part 2 2. Remove parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 4: Sliding Door Remote Control Removal Note 1. Open the clip and disconnect the exterior sliding door handle actuating rod. 2. Open the clip and disconnect the interior sliding door handle actuating cable. Item 12: Rivet Removal Note Page 4225 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Locations View 151-6 Page 6165 Multiple Junction Connector: Diagrams C316-C3206 Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Page 7843 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 2 Page 8668 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 4596 Canister Purge Control Valve: Service Precautions WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. Page 6464 Locations Page 6355 Page 9399 RH Rear Lamp C415, LH Rear Lamp C412 SJB C2280d Test O PINPOINT TEST O: ONE OR MORE PARKING, REAR OR LICENSE LAMP IS INOPERATIVE Locations View 151-8 Page 3027 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Technician Safety Information Heater Hose: Technician Safety Information WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Page 9610 Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or equivalent meeting Ford specification ESB-M4J58-A as follows: Surface Preparation 1. Bring vehicle inside and warm it to 60° F (16° C) or above. 2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. NOTE THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME. Mixing The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake frequently during use. Application 1. Mark location of open grid on the outside of the back window glass (performed in diagnostics). Place protective covering over the package tray as necessary. 2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should be at the center of the mask and tape gap must be no wider than the existing grid line. Other types of tape may be used but end results of the repair may not appear as visually acceptable due to ease of application and tape edge finish. 3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five (5) minutes drying time between coats) across the open grid line area using the brush applicator in the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area. Apply a minimum of six (6) coats of the grid repair compound. 4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown lacquer touch-up paint across the open line area first. Take care to paint only the area missing the color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at least five (5) minutes between coats. Apply six (6) coats of grid repair compound. NOTE THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER Page 6762 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Locations View 151-6 Description and Operation Fuel Line Coupler: Description and Operation FUEL LINES AND FITTINGS Fuel Line Assembly A fuel line assembly (Figure 84) consists of flexible hose and/or stainless steel seamless tubing, end fittings and tube nuts. The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wire braided covering. The fittings are inserted into the hose ends and crimped into place. The stainless steel tubing contains end fittings which are brazed to the tube. There are high pressure fuel lines that are identified by either 1/4-inch or 3/8-inch outer diameter and a low pressure fuel line identified by a 1/2-inch outer diameter. The low pressure fuel line has a quick-connect at one end for connection to the fuel rail. The other fittings used on the natural gas vehicle to connect fuel components are SAE O-ring face seal tube fittings. There are two end types: an O-ring face seal end and a straight thread end. On tee and elbow fittings, a washer and a positionable nut are provided to aid in orientation of the fitting. Page 9467 Recall 04V446000: Front Hub/Rotor/Bearing Replacement Brake Rotor/Disc: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 9029 Mechanical Returnless Fuel Pump Module (FPM) Page 9290 Headlamp Switch: Service Precautions CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. Page 3575 Part 2 Of 2 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 7: Radiator Alignment Pins Removal Note 1. Tie the radiator and the condenser to the upper radiator support using mechanics wire. ^ Allow 2 inches of slack in the condenser wire to allow for movement. ^ Remove the radiator alignment pins. Item 13: Transmission Cooler Tubes Removal Note Page 2129 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Page 4178 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 8679 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 Page 7174 Page 4183 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. Page 1702 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 8825 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 185 Inspection Page 7453 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustration(s) and table(s). Item 1: Recliner Handle Cover Removal Note Brake Pressure Switch Page 3990 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 1047 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Body - Cowl Panel Grille Breakage Cowl: All Technical Service Bulletins Body - Cowl Panel Grille Breakage TSB 04-17-6 09/06/04 COWL PANEL GRILL BREAKING FORD: 1999-2003 Windstar 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 1999-2003 Windstar and 2004-2005 Freestar/Monterey vehicles may exhibit the windshield cowl panel grille (leaf screen) breaking at the grille opening. ACTION To service, replace cowl panel with updated service part. Refer to Workshop Manual Section 501-02. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041706A Replace The 0.3 Hr. Windshield Cowl Panel Grille (Leaf Screen) DEALER CODING CONDITION BASIC PART NO. CODE 70022A68 01 Disclaimer Page 6632 Part 1 Of 3 Page 8217 direction. Inspect the alignment of the C-pillar wire striker in the latch. If striker is not centered, proceed as follows: Mark the edges of the striker. - Slightly loosen the screws. - Tap the striker into the correct position. - Tighten the screws. 5. NOTE: The vehicle may be equipped with either an M6 or M8 size bolt at this location. If the lower front portion of the sliding door does not meet the sliding door to front door flushness specification, proceed as follows: Loosen the lower roller bolt. - Move the bracket until the lower portion of the sliding door is flush with the lower portion of the front door. - Tighten the M6 size lower roller bolt to 12 Nm (9 lb-ft) or the M8 size bolt to 20 Nm (15 lb-ft). 6. If the upper front portion of the sliding door does not meet the sliding door to front door flushness specification or if the sliding door to quarter panel does not meet specification, proceed as follows: Mark the forward and rearward edges of the bracket. - Loosen the upper roller nuts. - Move the sliding door to gain flushness specification. - Tighten the nuts. 7. The B-pillar and C-pillar wire strikers should be centered after steps 5 and six 6 completed. For further adjustment, refer to steps 3 and 4. Page 2452 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Horn Switch: Service and Repair HORN SWITCH REMOVAL 1. Remove the driver air bag module 2. Remove the parts in the order indicated in the illustration and table. Item 3: Horn Switch Spring Removal Note 1. The 4 horn switch springs are not attached. To avoid losing the springs use caution when removing the horn switch. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a Cabin Air Filter Page 1498 P2270 - P2274: Testing and Inspection P2274 For diagnosis of code P2274 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8839 View 151-13 P1640 P1640 - P1644: Testing and Inspection P1640 For diagnosis of code P1640 refer to NOTE 23: NOTE 23: See Bi-Fuel CNG Models or Bi-Fuel LPG Models Testing for instructions on how to retrieve DTCs from the secondary module. See P1640 in Diagnostic Trouble Code (DTC) Descriptions for additional information. - Bi-Fuel CNG Models. - Bi-Fuel LPG Models. - Diagnostic Trouble Code (DTC) Descriptions. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Driver Page 1694 Page 7191 Control Module HVAC: Diagrams Electronic Manual Temperature Control (EMTC) Module Page 3845 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 8982 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 6388 Service Precautions Garage Door Opener Transmitter: Service Precautions WARNING: A garage door opening system that cannot stop or reverse itself after detecting an object in its path does not meet current federal safety standards. To decrease the risk of serious injury or death, do not use this HomeLink(R) universal transmitter with a door opening system that lacks stop and reverse features as required by federal standards. This includes any garage door opening system manufactured before April 1, 1982. Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 3001 Part 2 1. Refer to the chart for refrigerant oil adding amounts and methods of installation. Refrigerant Oil Adding for New A/C Compressor Installation NOTE: Service A/C compressors are shipped without refrigerant oil. 1. Rotate the old A/C compressor shaft 8 to 10 full rotations (clockwise) while collecting the refrigerant oil in a clean measuring cup. - If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), add the same amount plus the amount collected during refrigerant recovery. - If the amount of oil drained from the old A/C compressor is greater than 142 ml (5 ounces), add the same amount plus the amount collected during refrigerant recovery. - If the amount of oil drained from the old A/C compressor is less than 85 ml (3 ounces), add 85 ml (3 ounces) plus the amount collected during refrigerant recovery. Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation 1. Drill one half-inch hole in the old suction accumulator or receiver/drier cylinder and drain the oil into a clean measuring cup. 2. Add the quantity of oil drained, plus the amount collected during refrigerant recovery and 60 ml (2 ounces). Oil Injection Using a Dye/Lubricant Injector NOTE: If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector along with the refrigerant oil. 1. Evacuate the refrigerant system. 2. Assemble the dye/lubricant injector using the correct adapters to match the amount of PAG oil to be injected. 3. Verify that all the valves on the dye/lubricant injector are closed. Page 7101 5. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Disconnect the heater hoses at the floorpan bracket. 6. Support the rear axle with a jack stand. 7. Remove the track bar bolt. 8. Disconnect the LH rear wheel speed sensor electrical connector. 9. Remove the bolts and the two remaining line brackets. 10. Tilt the auxiliary heater outlet and inlet lines to drain any remaining coolant and remove the auxiliary heater outlet and inlet lines. INSTALLATION 1. To install, reverse the removal procedure. - Lubricate the coolant hoses with plain water only, if needed. Page 5286 Transmission Cooler: Service and Repair Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Special Tool(s) Material Removal and Installation NOTE: Vehicles that are equipped with a trailer tow package will have this type of a cooling system. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Removal and Installation Impact Sensor: Service and Repair Removal and Installation Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Page 3509 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 1007 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Charging System DTC Index P1246 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Charging System diagnostic information, See: Starting and Charging/Charging System/Testing and Inspection P0500 P0500 - P0504: Testing and Inspection P0500 For diagnosis of code P0500 refer to chart P0463-P0503 NOTE 6: Go to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection NOTE 8: Vehicle speed information is provided by the anti-lock brake system. Go to Antilock Brakes / Traction Control Systems. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection System Diagnosis P0165 - P0169: Testing and Inspection For diagnosis of code P0167 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1900 Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Service Precautions Fuel Temperature Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 1903 Page 3666 Part 4 Of 4 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 11: Coolant Pump Pulley Bolts Removal Note 1. Remove the engine mount nuts. Page 6437 Page 65 P0100 - P0104: Testing and Inspection P0104 For diagnosis of code P0104 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 241 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1399 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7495 Part 1 Specifications Alternator: Specifications ITEM..................................................................................................................................................... ...................................................SPECIFICATION Rating.............................................................................................61/135 amp (max) @ 1800-6000 generator RPM, approximately 500-2000 engine RPM Generator pulley ratio.................................... .............................................................................................................................................................. ...2.67:1 Voltage regulator type............................................................................................................ ..............................................Electronic internal with generator Generator Base Voltage........................................................................................................................................ .................................................................12.0 volts No Load at 2000 rpm.......................................... ..........................................................................................................................between 13.0 - 15.0 volts Load at 2000 rpm......................................................................................................................... .................................at least 65 amps above base voltage Locations View 151-27 Page 3976 Fuel Pressure Sensor/Switch: Description and Operation Natural Gas Fuel System INJECTION PRESSURE SENSOR Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 6676 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 8363 Page 2700 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity Without Auxiliary Climate Control ........................................................................................................ ........................................................ 10 oz (296 ml) With Auxiliary Climate Control ............................................................................................................. ........................................................ 12 oz (355 ml) Page 4359 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 3235 1. If the valve tappets are to be reused, they must be installed in their original location. Mark the valve tappets for location before removing. Items 8-11: Valve Spring Removal Note 1. CAUTION: The piston must be at the top of its stroke with both the intake and exhaust valves closed prior to removing the valve spring. CAUTION: If a valve drops into the cylinder, remove the cylinder head. Hold the valve in the cylinder head. Remove the spark plug. - Apply a minimum of 689 kPa (100 psi) of compressed air into the cylinder. 2. Using the special tool, compress the valve springs. 3. Remove the following: 1. Valve spring retainer key 2. Valve spring retainer 3. Valve spring 4. Valve stem seal Item 8: Valve Spring Retainer Key Installation Note 1. CAUTION: Do not release the compressed air from the cylinder until after the valve spring keys are installed. After installing the valve spring keys, release the air pressure from the cylinder. Install the spark plug. Items 3-1: Rocker Arm Installation Note Page 844 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5102 Item 7: Selector Lever Indicator Cable Removal Note 1. Position the selector lever indicator cable aside. 1 Loosen the screw. 2 Disconnect the cable. 3 Position the selector lever indicator cable aside. Page 5196 ^ Windstar, Freestar, Monterey, Taurus, and Sable with column shifter - Must face to the right rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 1) ^ Taurus and Sable with floor shifter - Must face to the rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 2) 10. Install one end of a 24" (61 cm) long piece of 5/16" (8 mm) vacuum hose to the 90° vent stem and secure with a small hose clamp. 11. Route the vacuum hose back and up to the cowl area and down next to the brake master cylinder. Carefully tie rap the hose in place next to the brake master cylinder (do not tie rap to brake lines), be sure the end of the hose is facing down and not directly above anything hot. Page 8193 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 6367 Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines 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 vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, 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 will be used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of Description and Operation for specific OBD catalyst monitor information. The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 121) and (Figure 122) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is utilized to monitor the light-off catalyst and the last group of sensors or stream 3 (HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a Page 2492 Page 9762 Page 8406 Console: Service and Repair FLOOR CONSOLE REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 4: Console Gasket/Mat Removal Note 1. The gasket mat is held in place by the sides of the console bin pressing against the console bracket. It can only be removed after the console bin has been removed. INSTALLATION 1. To install, reverse the removal procedure. Page 2041 Page 5090 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................................... 11 ft. lb. (15 Nm) Page 5123 Page 5617 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 7080 Part 3 3. Remove the parts in the order indicated in the illustrations and tables. Item 6: Storage Console Removal Note 1. Disconnect the electrical connector. Item 7: Upper Instrument Panel Finish Panel Removal Note 1. Disconnect the electrical connector. Item 8: Instrument Panel Bolt Removal Note Locations View 151-6 Page 3445 Clean and inspect the engine block and front cover as follows: - Pack the exposed portion of the oil pan with clean shop towels. - Plug the oil and coolant passages. - Clean the gasket surfaces. - Clean all surfaces requiring gasket sealant with metal surface cleaner. - Using compressed air, remove any remaining foreign material from the engine block and front cover. - Remove the shop towels from the oil pan. - Remove the plugs or seals from the oil and coolant passages. 2. Apply a small amount of silicone gasket and sealant as shown. 3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown. Timing Cover Torque Sequence 4. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence. NOTE: Use pipe sealant with tenon on studs No. 4, 6 and bolt No. 12. Install the engine front cover with the engine front cover studs in their original locations. Page 1068 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2829 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Item 6: Spark Plug Wire-to-Spark Plug Removal Note Page 7132 7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating. Close the valves on the deluxe injector loop kit. 9. NOTE: Leave all valves on the special tool closed when not in use. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle. Page 4661 Page 4626 Leak Detection Valve: Description and Operation CANISTER VENT SOLENOID Typical Canister Vent (CV) Solenoid During the EVAP Leak Check Monitor, the canister vent (CV) solenoid (Figure 105) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP Leak Check Monitor. Page 8577 Page 7675 D-Ring Installation Kit Page 6952 Cabin Temperature Sensor / Switch: Service and Repair IN-VEHICLE TEMPERATURE SENSOR REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Center Instrument Panel Finish Panel Removal Note 1. Remove the center instrument panel finish panel. INSTALLATION 1. To install, reverse the removal procedure. Locations Number One Cylinder: Locations Page 8421 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 6316 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Page 3633 Page 8255 Part 2 2. Remove parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 4: Sliding Door Remote Control Removal Note 1. Open the clip and disconnect the exterior sliding door handle actuating rod. 2. Open the clip and disconnect the interior sliding door handle actuating cable. Item 12: Rivet Removal Note Page 5755 Page 6927 Blower Motor Resistor: Description and Operation ELECTRONIC MANUAL TEMPERATURE CONTROL Blower Motor Resistor The blower motor resistor: is located on the heater core and evaporator core housing near the blower motor. - has three resistor elements mounted on the resistor board to provide four blower motor speeds. - depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. - has an overheating device (thermal limiter) that will open the resistor when the temperature reaches approximately 220°C (428°F), interrupting the blower motor operation in all speeds except high. - is serviced as an assembly. The thermal limiter cannot be reset and is not serviceable. Page 2568 Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 6126 Description and Operation Fuel Gauge Sender: Description and Operation FUEL PUMP MODULE Fuel Pump Module Page 9019 Page 6407 Page 2580 Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. Remove the front seat on the side with the affected side impact sensor. 4. Position the carpet aside to access the front row side impact sensor. 5. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 9529 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Brake Booster Sensor Page 1354 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1760 refer to chart Page 5233 1 Rotate the special tool. 2 Rotate the forcing screw while holding the front cover seal remover. 3 Remove the metal protector of the seal. Item 4: RH Rubber Seal Portion Removal Note 1. Remove the rubber portion of the seal. 1 Rotate the special tool. 2 Rotate the forcing screw while holding the front cover seal remover. 3 Remove the rubber portion of the seal. Item 4: RH Rubber Seal Portion Installation Note 1. Using the special tools, install the RH seal. Item 2: LH Rubber Seal Portion Installation Note 1. Using the special tool, install the LH differential seal. Locations View 151-16 Service Precautions Fuel Pressure Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 5928 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 8628 Page 4367 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 6106 Fuse: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Description and Operation Fuel Gauge Sender: Description and Operation FUEL PUMP MODULE Fuel Pump Module Page 1767 Throttle Plate Controller Check Operation The purpose of the TPPC is to control the throttle position to the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle signal. The TPPC interprets the duty cycle signal as follows: 0% <= DC < 5% - Out of range, limp home default position. - 5% <= DC < 6% - Commanded default position, closed. - 6% <= DC < 7% - Commanded default position. Used for key-on, engine off. - 7% <= DC < 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - 10% <= DC <= 92% - Normal operation, between 0 degrees (hard-stop) and 82%, 10% duty cycle = 0 degrees throttle angle, 92% duty cycle = 82 degrees throttle angle. - 92% < DC <= 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - 96% < DC <= 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate to be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The "H" driver is capable of positive or negative voltage to the Electronic Throttle Body Motor. Page 7022 Control Module HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL EATC Module The EATC module: is located in the instrument panel. - has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs). - utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble codes (DTCs). These DTCs direct the technician to the inoperative component. - display will switch between Celsius and Fahrenheit when the instrument cluster display is toggled. Page 5033 Page 855 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Heated Seat Module, Passenger Side Front Page 4958 Page 2150 Page 1739 Page 3389 3. Lower the RH side of the subframe 50.8 mm (2 inch). - Remove the bolts. - Lower the subframe. Item 6: Crankshaft Pulley Removal Note 1. Using the special tool, remove the crankshaft pulley. Item 7: Crankshaft Front Seal Removal Note 1. Using the special tool, remove the front crankshaft front seal. Item 7: Crankshaft Front Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation. Page 2177 Page 6241 Page 2822 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 347 P0265 - P0269: Testing and Inspection P0267 For diagnosis of code P0267 refer to chart B1219-B1317 / P0182-P1272 Page 1682 High Beam Relay: Testing and Inspection Page 7629 Item 11: Seat Assembly Removal Note 1. Remove the seat. Item 15: Safety Belt Buckle Pretensioner Assembly Removal Note 1. When removing the safety belt buckle pretensioner assembly, disconnect the safety belt buckle switch connector. INSTALLATION 1. To install, reverse the removal procedure. 2. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F), for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. After installing the passenger safety belt buckle pretensioner, rezero the occupant classification sensor. 1 Connect all passenger seat connector(s). Do not reactivate the SRS at this time. 2 Connect the battery ground cable. 3 Turn the ignition switch to the ON position. 4 With the front passenger seat empty, use the scan tool to trigger the active command and rezero the occupant classification sensor. 3. Disconnect the battery ground cable. 4. When installing the safety belt buckle pretensioner: 1 Remove the restraint system diagnostic tool from the safety belt buckle pretensioner. 2 Connect the safety belt buckle pretensioner electrical connector. 3 Connect the battery ground cable. 4 With the restraint system diagnostic tools installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats Door Ajar Switch, Left Front View 151-18 Page 1907 Air Bag Control Module: Locations View 151-8 Page 5303 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 1031 P1265 - P1269: Testing and Inspection P1266 OBD II - Base Gasoline For diagnosis of code P1266 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2988 1. Prior to recovering, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer. 3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer. 4. Once the refrigerant service center has recovered the refrigerant, switch OFF the power supply. 5. Allow the system to set for about two minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat steps 3 through 5 until the vacuum level remains stable for two minutes. 7. Carry out the required repairs. Page 100 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6067 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 2036 Page 9209 Brake Lamp: Pinpoint Tests High Mounted Stoplamp C475 RH Rear Lamp C415, LH Rear Lamp C412 Page 592 P0550 - P0554: Testing and Inspection P0553 For diagnosis of code P0553 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0350 P0350 - P0354: Testing and Inspection P0350 For diagnosis of code P0350 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 799 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Left Front Page 4838 Fuel Pump Module (For Returnable Fuel Systems) Page 3218 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. A related DTC will also be set when this fault 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 cam 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 two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Page 1475 Inspection Master Window/Door Lock/Unlock Switch View 151-18 Page 461 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1015 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Specifications Alignment Specifications Page 8539 - UA Ebony - WT Performance White Accent Body Color Code - B2 Harvest Gold - TF Graphite Page 3033 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 4119 Intake Air Temperature Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Specifications Wheel Fastener: Specifications Wheel nut fastener .............................................................................................................................. ................................................... 135 Nm (100 ft.lbs.) Page 5049 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 1940 Locations View 151-6 Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY Special Tool(s) SPECIAL TOOL(S) Refrigerant System Recovery NOTE: - Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant system recovery, evacuation, and charging may be accomplished using a separate recovery station, vacuum pump, charging meter, and manifold gauge set. - Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Page 4521 Drivetrain - Front Wheel Bearing Whistling Noise Wheel Bearing: Customer Interest Drivetrain - Front Wheel Bearing Whistling Noise TSB 04-16-13 08/23/04 NOISE FROM FRONT WHEEL HUB BEARING FORD: 2004 Freestar MERCURY: 2004 Monterey ISSUE Some Freestar/Monterey vehicles may exhibit a high pitched whistling/squealing noise from the front exterior while driving, accelerating and/or cruising. The noise usually starts after 5-10 minutes of driving and goes away with steering wheel input. ACTION To service, replace the front wheel hub bearing that is causing the noise. Refer to Workshop Manual Section 204-00 for procedures. The wheel hub bearings used in production and service have been updated. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041613A Replace One 1.0 Hr. Front Wheel Hub Bearing (Includes Time For Road Test) 041613B Replace Both 1.6 Hr. Front Wheel Hub Bearings (Includes Time For Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 1104 42 Disclaimer Page 1644 Page 3363 Part 2 Of 4 Part 3 Of 4 Page 7273 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Restraints - Seat Belts Slow to Retract Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract TSB 05-16-11 08/22/05 SAFETY BELT RETRACTION SPEED FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2004-2006 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006 Monterey 2005-2006 Mariner This article supersedes TSB 04-24-21 to update the vehicle model years. ISSUE A service kit is now available to improve safety belt retraction speed. ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20A for additional information. NOTE TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE THREE VEHICLES. NOTE FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES. ^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on vehicles built on/after 6/16/2003. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004. ^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004. Page 8275 Page 7792 Page 9264 Page 7598 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 6689 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Master Window/Door Lock/Unlock Switch View 151-18 ABS - Module Replacement Service Tip Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 3039 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Page 727 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6958 Compressor Clutch: Adjustments A/C CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specifications. Page 9553 PINPOINT TEST W: THE TRAILER LAMPS ARE INOPERATIVE Test W1 Test W1-W4 Front Parking Aid Speaker Parking Assist Warning Indicator: Service and Repair Front Parking Aid Speaker PARKING AID SPEAKER - FRONT REMOVAL 1. Remove the RH instrument panel steering column reinforcement. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8497 ABS - Module Replacement Service Tip Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 7236 Page 5313 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 2578 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. - Make sure the radiator support and front impact severity sensor mating surfaces are clean and debris free. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure First Row SIDE IMPACT SENSOR - FIRST ROW Page 989 P1230 - P1234: Testing and Inspection P1233 For diagnosis of code P1233 refer to chart P1151-P1309 NOTE 20: Go to Information Bus for REM (Rear Electronics Module) self-test diagnostics. See: Powertrain Management/Computers and Control Systems/Information Bus/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 135 P0130 - P0134: Testing and Inspection P0133 For diagnosis of code P0133 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 542 P0480 - P0484: Testing and Inspection P0482 For diagnosis of code P0482 refer to chart P0463-P0503 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5364 Item 3: Lower Control Arm Ball Joint Pinch Bolt Removal Note 1. Remove and discard the nut and bolt. Item 5: Halfshaft Assembly Removal Note 1. Separate the rear axle halfshaft assembly from the hub. Using the special tools, press the outboard CV joint until it is loose in the hub. Remove the special tool. Separate the outboard CV joint from the hub. 2. CAUTION: Do not damage the transmission differential seal. Remove the halfshaft with both hands. Item 5: Halfshaft Assembly Installation Note 1. CAUTION: Install a new circlip every time the halfshaft is removed from the transmission differential. On the RH halfshaft only, Install a new axle circlip in the groove in the inboard CV joint stub shaft. ^ Start one end in the groove and work the circlip over the shaft and into the groove to prevent the clip from overexpanding. Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 7117 6. Remove the line brackets and the front auxiliary evaporator outlet and inlet lines. 7. Disconnect the fittings at the rear tube-in-tube fitting. - Discard the O-ring seals. 8. Remove the bolts and the line brackets. 9. Remove the auxiliary tube-in-tube assembly. INSTALLATION 1. To install, reverse the removal procedure. - Install new O-ring seals lubricated in clean mineral oil. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Evacuate, leak test and charge the refrigerant system. Page 9501 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Page 9371 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 2959 11. Remove the plug from the cooler tube fitting. 12. Remove the flex hose from the cooler tube. 13. NOTE: Clean the cooler tube fitting before installing it to verify a good connection and to prevent any leaks. Install the lower cooler tube. 14. Install the lower retaining clip 15. Fill the transaxle with clean automatic transmission fluid. 16. Start the engine and move the transaxle range selector lever through all the ranges allowing the transaxle to engage in each position. 17. Check the transaxle at normal operating temperature. Fluid should be within the crosshatched area of the fluid level indicator. If the fluid is not within the crosshatched area add fluid in 0.2365 liter (1/2 pint) increments until the correct level is achieved. Page 1668 Control Module HVAC: Diagrams Electronic Manual Temperature Control (EMTC) Module Page 5778 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 7904 Parking Assist Control Module: Diagrams Page 9487 Headlamp Switch: Testing and Inspection Page 4209 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 456 P0355 - P0359: Testing and Inspection P0359 For diagnosis of code P0359 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Traction Control - Short Duration Activation Steering Angle Sensor: Customer Interest Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Specifications Idle Speed: Specifications Idle Speed is Computer Controlled Hot Idle ................................................................................................................................................ .............................................................. 700-730 rpm Page 6734 Steering Wheel: Service and Repair STEERING WHEEL AUDIO CONTROLS REMOVAL 1. Remove the driver air bag module. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Accessory Delay Relay 1 Page 7130 approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses. - Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves. 2. Verify that the valves on the fluorescent dye injector are closed. 3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set. Fluorescent Dye Injection - Using a Dye Injector Loop Kit NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C. Page 4708 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 5668 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 8676 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Specifications Engine Oil Pressure: Specifications Oil Pressure (Hot 2,500 rpm) ............................................................................................................... ................................................................. 40-125 psi Page 1356 Inspection Specifications Compression Check: Specifications Part 1 0f 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 1131 Inspection Page 6392 Page 8981 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 7997 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling Pinpoint Test. NOTE: Refer to Multimeter User's Manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, install a new switch; otherwise, return to the calling Pinpoint Test. Page 6684 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Page 5267 Item 7: Selector Lever Indicator Cable Removal Note 1. Position the selector lever indicator cable aside. 1 Loosen the screw. 2 Disconnect the cable. 3 Position the selector lever indicator cable aside. Page 9037 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Description and Operation Muffler: Description and Operation 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 it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Page 7565 Recall - Front Hub & Rotor Replacement Technical Service Bulletin # 04S24S1 Date: 060322 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated on September 2, 2004 Page 2754 Part 1 Of 2 Part 2 Of 2 Front Ride Height Measurement Part 1 Of 2 Page 4867 Main Relay (Computer/Fuel System): Testing and Inspection Page 6222 ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Locations Page 4847 Fuel Temperature Sensor: Description and Operation ENGINE FUEL TEMPERATURE SENSOR Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 3502 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 3125 Relay Box: Application and ID Bussed Electrical Center (BEC) Page 7367 Page 843 P0970 - P0974: Testing and Inspection P0974 For diagnosis of code P0974 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 2588 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Page 672 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9352 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 Page 7387 1. Disconnect the clockspring electrical connectors and detach them from the bracket. 2. Remove the clockspring wire harness from its holders. Item 15: Clockspring Removal Note 1. Release the three clips and slide the clockspring off the steering column. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. 1. WARNING: Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury. Page 90 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Crankshaft Main Bearing Seal: Service and Repair Flexplate or Flywheel and Crankshaft Rear Seal Special Tools And Equipment Special Tools And Equipment Special Tool(s) Page 6259 Relay Box: Application and ID Bussed Electrical Center (BEC) Locations View 151-13 Page 1364 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift For diagnosis of code P1780 refer to system being tested: Transmission Control If there is no link in the chart then: This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3030 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 3241 1. If the valve tappets are to be reused, they must be installed in their original location. Mark the valve tappets for location before removing. Items 8-11: Valve Spring Removal Note 1. CAUTION: The piston must be at the top of its stroke with both the intake and exhaust valves closed prior to removing the valve spring. CAUTION: If a valve drops into the cylinder, remove the cylinder head. Hold the valve in the cylinder head. Remove the spark plug. - Apply a minimum of 689 kPa (100 psi) of compressed air into the cylinder. 2. Using the special tool, compress the valve springs. 3. Remove the following: 1. Valve spring retainer key 2. Valve spring retainer 3. Valve spring 4. Valve stem seal Item 8: Valve Spring Retainer Key Installation Note 1. CAUTION: Do not release the compressed air from the cylinder until after the valve spring keys are installed. After installing the valve spring keys, release the air pressure from the cylinder. Install the spark plug. Items 3-1: Rocker Arm Installation Note Page 7632 Part 1 Page 551 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 166 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0151 refer to chart Page 2585 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. Page 8978 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 201 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Power Window Switch, RH Side Front Page 3673 Typical Bank 1 Catalyst Two HO2S Configuration Typical Bank 1 Catalyst Three HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of carbon monoxide (CO), unburned hydrocarbons (HCs) and oxides of nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter through another HO2S mounted in the rear exhaust pipe (Figure 124) and then on into the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 125). 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 two 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 that vehicle. Page 755 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0755 refer to chart If there is no link in the chart then: Page 4714 Specifications Torque Converter: Specifications Torque converter-to-flexplate nuts ........................................................................................................................................................... 35 Nm (26 ft. lbs.) Locations View 151-6 Page 2739 Page 457 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 4654 Page 7627 Part 1 Page 8416 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 3119 Locations Page 5922 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 6373 Note: The bussed electrical center is located in the engine compartment. Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Page 236 P0190 - P0194: Testing and Inspection P0191 For diagnosis of code P0191 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9727 Wiper Switch: Testing and Inspection Page 3337 Oil Pan: Service and Repair Oil Pan, Oil Pump Screen and Pickup Tube, Oil Pan Baffle Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the starter. 3. Remove the dual converter Y-pipe. 4. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 198 Inspection Page 7535 Interior - Under Column Access Door Warped/Broken Steering Column Cover: Customer Interest Interior - Under Column Access Door Warped/Broken TSB 04-22-9 11/15/04 ACCESS DOOR WARPED OR BREAKING OFF FROM THE UNDERSIDE OF THE STEERING WHEEL SHROUD FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit the access door, located on the underside of the steering wheel shroud, being warped or breaking off. ACTION Replace the access door. The access door can now be serviced separately, it is no longer necessary to replace the entire steering wheel shroud. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE ACCESS DOOR HAS BEEN BROKEN OFF PROCEED TO STEP 2. 1. If the access door is being replaced due to warping, it must first be removed. Remove the door by repeatedly opening and closing the door. The molded hinge area of the door will fatigue and the door will break off leaving a clean edge. 2. Replace the access door with the correct color service part. 3. The new door must be slid into place, and will be held in place with the tabs on each side of the door. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042209A Replace Access Door On 0.2 Hr. The Steering Wheel (Includes Time To Remove The Old Door If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 3L518 01 Page 1947 Page 8675 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 Page 9462 View 151-19 Page 9541 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 6127 Page 129 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Right Rear Page 6171 Page 7269 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Adjustments Front Door Striker: Adjustments STRIKER ADJUSTMENT 1. Loosen the door latch striker bolts. 2. Adjust the door latch striker plate from side-to-side or up-and-down as necessary. 3. Tighten the door latch striker plate bolts. Page 286 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0208 refer to chart Page 1904 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Locations View 151-15 Connector Views Fuse Block: Connector Views Bussed Electrical Center (BEC) Page 9678 3. Position the door window glass halfway down to gain access to the door window glass rivets. - Remove the rivets. Item 4: Rivet Removal Removal Note 1. Remove the rivets. Item 5: Front Door Window Regulator Removal Note 1. Disconnect the electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Rivet Installation Note 1. Using the special tool, install the rivets. Item 1: Rivet Installation Note 1. Using the special tool, install the rivets. Page 894 P1100 - P1104: Testing and Inspection P1101 For diagnosis of code P1101 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7147 Refrigerant Oil: Service Precautions CAUTION: 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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Page 9647 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 8987 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. P0280 P0280 - P0284: Testing and Inspection P0280 For diagnosis of code P0280 refer to chart B1219-B1317 / P0182-P1272 Page 444 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7199 Ambient Temperature Sensor / Switch HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Ambient Temperature Sensor The ambient temperature sensor signal is received by the smart junction box (SJB) which communicates it to the EATC module via the vehicles SCP network. Page 5906 Vacuum Brake Booster: Service and Repair Brake Master Cylinder and Brake Booster WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Disconnect the battery. 2. Remove the air cleaner assembly. Page 1701 Page 4422 Page 7372 Part 1 Page 6445 Relay Box: Locations Bussed Electrical Center (BEC) Page 8413 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Electrical - Wiring Harness Replacement Guidelines Wiring Harness: All Technical Service Bulletins Electrical - Wiring Harness Replacement Guidelines TSB 06-17-8 09/04/06 SERVICE WIRING HARNESS REPLACEMENT GUIDELINES - SERVICE TIPS FORD: 2000-2003 Focus 2005-2006 Focus 2005-2007 Mustang 2002 Ranger 2004-2007 F-150, Freestar 2005 Escape 2005-2007 Expedition 2007 E-Series 2006-2007 F-650, F-750 LINCOLN: 2005-2007 Navigator 2006-2007 Mark LI MERCURY: 2004-2007 Monterey 2005 Mariner This article supersedes TSB 05-16-12 to update vehicle lines and model years. ISSUE Ford Motor Company has "consolidated" high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used. ACTION Should replacement of a production wire harness become necessary, determine whether the harness is to be used in a WET or DRY environment, then refer to the appropriate Service Procedure below. SERVICE PROCEDURE NOTE IF UNSURE WHETHER THE ENVIRONMENT FOR THE HARNESS WILL BE "WET" OR "DRY" ALWAYS TREAT AS A "WET" ENVIRONMENT. Extra Open Connectors - Procedure For "Dry" Environment/Interior Wiring Harness: Any extra open connectors should be tucked, folded, and taped out of the way to avoid creating a rattle or becoming loose (Figure 1). If space allows, Page 3415 3. Using the special tools, install the crankshaft front seal. Item 8: Crankshaft Pulley Installation Note 1. Lower the RH side of the subframe 50.8 mm (2 inch) - Remove the bolts. - Lower the subframe. 2. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley. Using the special tool, install the crankshaft pulley. 3. Raise the subframe into position, then install the bolts. 4. Connect the RH front anti-lock brake wheel sensor electrical connector. Page 650 - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0708 refer to chart If there is no link in the chart then: Page 3723 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 1651 Page 2985 Refrigerant: Testing and Inspection Electronic Leak Detection ELECTRONIC LEAK DETECTION H10PM Refrigerant Leak Detector With Battery SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing. 1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. 2. If a leak is found, recover the refrigerant. - Repair the system. - Test the system for normal operation. Page 9354 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 Page 9534 Symbols Part 3 System Diagnosis P1485 - P1489: Testing and Inspection For diagnosis of code P1489 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2646 Special Tool(s) Locations View 151-5 Page 7460 - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 2. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining ear. 3. CAUTION: Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Align the bladder to the seat cushion pan. Item 5: Electronic Control Unit (ECU) Installation Note 1. Slide the electronic control unit (ECU) into the seat cushion pan bracket and install the rivets. - The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). Item 8: Seat Cushion Trim Cover Installation Note 1. CAUTION: - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. Item 9: Seat Cushion Foam Pad Installation Note 1. CAUTION: Inspect the seat cushion pad and pan for any foreign objects before installing the seat cushion pad to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad to the seat cushion pan and set in place. 2. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Locations View 151-6 Page 7939 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR REMOVAL 1. Remove the front or rear bumper cover. 2. NOTE: Rear parking aid sensor shown, front parking aid sensor similar. Remove the parts in the order indicated in the illustration and table. Item 2: Parking Aid Sensor Removal Note 1. Release the tabs and remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Page 1013 P1260 - P1264: Testing and Inspection P1261 OBD II - Base Gasoline For diagnosis of code P1261 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 2332 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 6871 View 151-8 Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s), Part 1 Page 1484 Inspection Page 7929 View 151-14 System Diagnosis P1240 - P1244: Testing and Inspection For diagnosis of code P1244 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Transaxle Cooling Inspection and Verification CAUTION: When internal wear or damage occurs in the transaxle, metal particles, clutch plate material, band material can travel into the fluid cooler tubes, fluid coolers (internal and external). These contaminants are a major cause of recurring transaxle concerns. To prevent further concerns, all these foreign contaminants need to be removed prior to placing the transaxle back into place. Refer to Transmission Fluid Cooler - Backflushing and Cleaning. 1. Visually inspect for obvious signs of mechanical damage, incorrect component installation, and system leaks. ^ Install a new or remanufactured radiator if evidence of a leak is found. ^ Install a new OTA cooler if evidence of a leak is found. Refer to Transmission Fluid Cooler. 2. If the visual inspection shows no obvious signs of mechanical damage, incorrect component installation, and system leaks, GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Page 9124 View 151-22 Page 6941 Blower Motor Switch: Description and Operation Electronic Automatic Temperature Control BLOWER MOTOR SPEED CONTROL The blower speed control: - is located on the heater core and evaporator core housing near the blower motor. - PWM signals from the EATC module to control a high-current, variable ground feed for the blower motor. - varies the blower motor speed and is controlled by the EATC module software. - has a delay function to provide a gradual increase or decrease in blower motor speed under all conditions. Page 8551 Page 691 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 7148 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) SPECIAL TOOL(S) Refrigerant Oil Adding CAUTION: 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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Part 1 Page 358 P0270 - P0274: Testing and Inspection P0273 For diagnosis of code P0273 refer to chart B1219-B1317 / P0182-P1272 Page 8707 View 151-20 Trailer Tow Relay, Right Turn Page 4910 Page 4699 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 789 Inspection Page 8811 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 5952 Page 1941 Starter Relay: Testing and Inspection Page 6866 View 151-8 Page 9327 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 Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 4942 Throttle Body: Description and Operation Electronic Throttle Body (ETB) ELECTRONIC THROTTLE BODY (ETB) The Gen II electronic throttle body (Figure 133) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2 times stronger than the main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (48 Km). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to avoid the throttle from binding in the bore (-0.75 degree). This hard stop setting is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle and idle quality and eliminates the need for IAC bypass actuator. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires four wires. 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Page 8958 Clock: Service and Repair CLOCK REMOVAL 1. Remove the parts in the order indicated in the illustration table. Item 1: Center Register Panel Removal Note 1. The center register panel is held in place by spring clips located on the panel. INSTALLATION 1. To install, reverse the removal procedure. Page 7002 Condenser HVAC: Description and Operation CONDENSER CORE NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Locations View 151-2 Recall 03V457000: Power Steering Line Inspection Power Steering Line/Hose: Recalls Recall 03V457000: Power Steering Line Inspection DEFECT: On certain minivans, the power steering low-pressure line may not be fully seated at the rack and pinion steering gear. If this line becomes disconnected, it may create the potential for fluid to come into contact with the exhaust system, which could result in smoke or fire. REMEDY: Dealers will inspect the power steering low-pressure line to ensure that it is seated properly at the rack and pinion steering gear. The manufacturer has reported that owner notification began November 10, 2003. Owners may contact Ford at 1-800-392-3673. Page 4936 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9299 Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Brake Pedal Position Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position Switch BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 7809 Attach the seat cushion trim cover J-clips to the seat cushion pan. Item 12: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 15: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 16: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Page 1067 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1277 refer to chart Electrical - ABS/TCS/Park Brake Lamps Flickering Wiring Harness: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 2278 Brake Light Switch: Service and Repair STOPLAMP SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. System Diagnosis P0580 - P0584: Testing and Inspection For diagnosis of P0581 refer to chart DTC Index P0500-P1572 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection Locations View 151-10 Page 7381 Clockspring Assembly / Spiral Cable: Vehicle Damage Warnings CAUTION: - Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. - Make sure the road wheels are in the straight-ahead position and the clockspring is centered before installing the clockspring. Page 7830 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Install the driver seat. Do not reactivate the supplemental restraint system as instructed to do so in the seat removal and installation procedure at this time. - After installation, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket or the wire harness do not come in contact with any other part of the seat that may cause damage. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 7. Connect the battery ground cable. 8. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Page 7499 1. NOTE: Due to seat options, some components, connectors and harnesses may or may not be present. If equipped, attach the climate control duct and connect the backrest thermal electric device electrical connector. 2. NOTE: Due to seat options, some components, connectors and harnesses may or may not be present. If equipped, connect the seat cushion heated seat element. Item 17: Side Air Bag Module Connector Installation Note 1. Attach the side air bag module electrical connector and wire harness pin-type retainers to the seat riser and cushion pan. Driver Safety Belt Retractor Pretensioner Page 7781 Seat Belt Buckle Switch: Description and Operation SAFETY BELT SWITCH As part of the supplemental restraint system (SRS), the driver and passenger safety belt buckles are equipped with hall-effect sensors. The safety belt switches indicate to the restraints control module (RCM) whether the safety belt buckles are buckled or unbuckled. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The safety belt switches are also used for the driver safety belt warning system and the driver and passenger belt minder. Refer to Seat Belt Systems. Page 2560 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 6644 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9036 Air Bag(s) Arming and Disarming: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. Page 9304 Page 8573 View 151-16 Page 2428 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The heated oxygen sensor (HO2S) (Figure 38) 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 temperatures of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will turn on the heater by providing the ground when the proper conditions occur. Since model year 1998 a high power HO2S heater and heater control system have been installed on the Stream 1 HO2S sensors of most vehicles. The high power heater reaches closed loop fuel control temperatures faster, which allows closed loop engine operation sooner. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. P2270 P2270 - P2274: Testing and Inspection P2270 For diagnosis of code P2270 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P1506 P1505 - P1509: Testing and Inspection P1506 For diagnosis of code P1506 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Power Steering Pressure Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Power Steering Pressure (PSP) Switch The power steering pressure (PSP) switch (Figure 45) 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 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Heating and Ventilation Heater Core: Description and Operation Heating and Ventilation HEATER CORE The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Page 9668 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front P1125 P1125 - P1129: Testing and Inspection P1125 For diagnosis of code P1125 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 89 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0113 refer to the Base Gasoline Diagnostic Chart: P0112-P0147 Page 2876 2. Fill the engine cooling system. Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment With Message Center COMPASS ZONE ADJUSTMENT - WITH MESSAGE CENTER 1. NOTE: The compass zone setting is preset from the factory to Zone 8. Determine which magnetic zone you are in for your geographic location. 2. Turn the ignition key to the START position. 3. Press the message center switch INFO button until the compass information is displayed. 4. Press the RESET button until RESET FOR ZONE is displayed in the message center display. 5. NOTE: To exit the compass zone adjustment mode before carrying out a compass zone adjustment, press the INFO button. Press the RESET button until SETUP ZONE XX is displayed in the message center display. 6. Press the SETUP button repeatedly until the correct zone setting for your geographic location is displayed. 7. Press the RESET button to exit the zone setting mode and lock your individual zone. Without Message Center COMPASS ZONE ADJUSTMENT - WITHOUT MESSAGE CENTER Output Shaft Speed Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed Sensor OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (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 generated. Page 4325 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 665 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Parking Aid Sensor, Front, Outer Left Page 4290 Main Relay (Computer/Fuel System): Testing and Inspection Page 3511 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Locations View 151-5 Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor INTAKE AIR TEMPERATURE SENSOR Typical Stane Alone/Non-integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange Type MAF Sensor The intake air temperature (IAT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - If removing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Page 9760 Windshield Washer Switch: Testing and Inspection Page 6981 11. Pull the seal from the A/C compressor. INSTALLATION 1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Clean the A/C compressor nose area. 2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with mineral oil or equivalent. 3. Position the shaft seal and the special tool over the A/C compressor shaft. 4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated. Page 174 Inspection Page 6031 The chart information summarizes two (2) recommended methods of charging. NOTE COLD BATTERIES WILL NOT READILY ACCEPT A CHARGE. THEREFORE, BATTERIES SHOULD BE ALLOWED TO WARM TO APPROXIMATELY 41° F (5° C) BEFORE CHARGING. THIS MAY REQUIRE 4 TO 8 HOURS AT ROOM TEMPERATURE. A battery which has been completely discharged and left in that condition for a prolonged time (such as an unsold vehicle) may be slow to accept a charge initially, and in some cases may not accept a charge at the normal charger setting. When batteries are in this condition, charging can be started by use of the "dead battery" feature on chargers so equipped. Follow charger manufacturer's instructions for use of dead battery switch. If switch is the spring-loaded type, it may need to be held in the ON position for up to 3 minutes. NOTE THE BATTERY EYE MAY REMAIN RED FOR A PERIOD OF TIME (UP TO SEVERAL DAYS), EVEN AFTER THE BATTERY IS FULLY CHARGED, BECAUSE THE ACID IS NOT YET FULLY MIXED. For additional information, refer to the PTS Website, web based Technician training "Fix It Right The First Time" course "Battery Testing and Charging 34G02W0" (website). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT070508 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 10655 42 Disclaimer Page 9411 Page 7755 Page 2856 Evaporative Canister Filter: Service and Repair DUST SEPARATOR REMOVAL 1. With the vehicle in NEUTRAL, position on a hoist. 2. WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4035 13. Install the special tool between the fuel supply line and the fuel supply manifold. Page 8224 1. If equipped with power mirrors, disconnect the electrical connector. Item 4: Window Regulator Control Switch Panel Removal Note 1. If equipped, disconnect the electrical connector(s). INSTALLATION 1. To install, reverse the removal procedure. Page 5756 Page 2485 Locations View 151-13 Page 2573 Impact Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. - The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. - The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Page 9196 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 Page 2374 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 4005 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 1282 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4800 Specifications Connecting Rod Bearing: Specifications Connecting rod bearing bore diameter ................................................................................................................ 61.635-61.655 mm (2.4266-2.4274 inch) Connecting rod bearing-to-crankshaft clearance-desired ............................................................................................ 0.025-0.035 mm (0.001-0.0014 inch) Connecting rod bearing-to-crankshaft clearance-allowable .................................................................................... 0.022-0.069 mm (0.00086-0.0027 inch) Recall - P/S Low Pressure Line Defect Technical Service Bulletin # 03S09 Date: 031101 Page 1601 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer P1405 P1405 - P1409: Testing and Inspection P1405 For diagnosis of code P1405 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9336 92-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 3310 Drive Belt: Service and Repair Accessory Drive Belt, Tensioner and Pulley 1. With the vehicle in neutral, position it on a hoist. 2. Remove the parts in the order indicated in the illustration and table. Part 1 0f 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Accessory Drive Belt Removal Note Page 5063 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 648 P0705 - P0709: Testing and Inspection P0708 Torqshift For diagnosis of code P0708 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Testing and Inspection Mini ISO Relay: Testing and Inspection Page 6667 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Page 4070 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE ABS - Module Replacement Service Tip Yaw Rate Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 9319 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 6937 View 151-12 Locations View 151-11 Page 8673 Symbols Part 5 Page 6368 Page 9754 4. Remove the parts in the order indicated in the illustration and table. Item 3: Windshield Washer Reservoir Bolts Removal Note Page 1681 Page 8012 Page 5698 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Master Window/Door Lock/Unlock Switch Power Door Lock Switch: Diagrams Master Window/Door Lock/Unlock Switch Page 8154 Symbols Part 3 Service Precautions Expansion Block/Orifice Tube: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 1756 Page 3369 4. NOTE: The lower intake manifold must be installed within four minutes of applying sealant. Position the lower intake manifold. 1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting points (at the front and rear seal). 2. Position the lower intake manifold. Items 6-5: Lower Intake Manifold Bolt Installation Note 1. NOTE: Make sure the bolts are installed in the correct locations. Install the six long bolts. 2. Install the eight short bolts. P0125 P0125 - P0129: Testing and Inspection P0125 For diagnosis of code P0125 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Customer Safety Information Impact Sensor: Customer Safety Information WARNING: The restraints control module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been involved in a collision in which the vehicle center tunnel area has been damaged, inspect the RCM mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Page 1036 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P2100 P2100 - P2104: Testing and Inspection P2100 For diagnosis of code P2100 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The fuel tank pressure (FTP) sensor (Figure 103) or inline fuel tank pressure (FTP) sensor (Figure 104) is used to measure the fuel tank pressure during the EVAP Leak Check Monitor. Page 5564 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 9028 Fuel Pump Module (For Returnable Fuel Systems) Locations View 151-5 ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 7192 Page 4999 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 1766 Electronic Throttle Monitor Operation, Part 1 Electronic Throttle Monitor Operation, Part 2 Accelerator and Throttle Position Sensor Inputs Accelerator Pedal Position Sensor Check Accelerator Pedal Position Sensor Check: Throttle Position Sensor Check Throttle Position Sensor Check: Throttle Plate Position Controller (TPPC) Outputs Page 3343 Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 6763 View 151-9 Page 6098 Page 8930 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 2149 Page 1158 Inspection Page 7655 Page 3848 Diagrams Power Trunk / Liftgate Control Module: Diagrams Page 4927 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH REMOVAL 1. Remove the jack access cover on the RH side interior rear quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 558 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Component Locations Page 3364 Part 4 Of 4 6. Remove the parts in the order indicated in the illustrations and tables. 7. To install, reverse the removal procedure. 8. Fill and bleed the cooling system. Item 4: Cable Bracket Stud Bolt Removal Note 1. Remove the engine harness retainer from the stud bolt. Item 17: LH Spark Plug Wire Assembly Removal Note 1. CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the spark plug wires from the spark plugs and the ignition coil. 2. Remove the pin-type retainers and the spark plug wires as an assembly. Page 3057 Page 1365 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Engine Control If there is no link in the chart then: This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7661 Page 8562 Power Sliding Door Module: Service Precautions WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. Main Light Switch View 151-8 P0960 P0960 - P0964: Testing and Inspection P0960 4R70W For diagnosis of code P0960 refer to chart Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle P1270 P1270 - P1274: Testing and Inspection P1270 For diagnosis of code P1270 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4477 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Page 8071 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 P0537 P0535 - P0539: Testing and Inspection P0537 For diagnosis of code P0537 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6865 View 151-27 Page 8649 Part 1 Page 6627 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Page 8096 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 2527 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 4861 Inertia Fuel Shutoff Switch: Description and Operation Natural Gas Fuel System Inertia Fuel Shutoff (IFS) Switch Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 87) is used in conjunction with electric fuel close valves. The purpose of the IFS switch is to close the fuel shut-off valves if a crash occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and closes the electric fuel shut-off valve. Once the switch is open, it must be manually reset before restarting the vehicle. On some vehicles a fuel reset light illuminates. Refer to the Owner Guide for the location of the IFS. Inertia Fuel Shutoff (IFS) Switch Reset RESET INSTRUCTIONS 1. Turn key off. 2. Check for natural gas leaks in the engine compartment. 3. NOTE: In the closed position, the button can be depressed an additional 1.57 cm (1/16 inch) against a spring. If no natural gas leak is apparent, reset the IFS by pushing the reset button on the top of the switch (refer to Owner Guide). 4. Turn key to on or start position for a few seconds, then off again. 5. WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. Again, check for leaking natural gas. Page 9363 92-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Technician Safety Information Heater Hose: Technician Safety Information WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Page 4425 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6398 Page 2642 Seat Sensor/Switch: Service Precautions WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Page 7986 73III Automotive Meter Page 1687 Page 2553 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 6358 Electrical - ABS/TCS/Park Brake Lamps Flickering Parking Brake Warning Lamp: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). System Diagnosis P1305 - P1309: Testing and Inspection For diagnosis of code P1309 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6246 Relay Box: Diagrams Smart Junction Box (SJB) Page 7927 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 9123 View 151-19 P0210 P0210 - P0214: Testing and Inspection P0210 For diagnosis of code P0210 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 6018 Page 3737 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 8652 3. Remove and discard all the hog rings (one shown) and remove the cushion trim cover. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Bucket Seat, Second Row REAR SEAT CUSHION - BUCKET SEAT, SECOND ROW DISASSEMBLY 1. NOTE: LH seat shown, RH seat is similar. Remove the bucket seat, second row. Page 5446 View 151-6 Page 7483 P0102 P0100 - P0104: Testing and Inspection P0102 For diagnosis of code P0102 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5290 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 2: Transmission Fluid Cooler Tubes (at Transaxle) Removal Note 1. Depress the tabs on the plastic insert retainer and remove the cooler line from the fitting. Page 3564 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 2 Page 2053 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 7227 Page 1544 INSTALLATION 1. To install, reverse the removal procedure. Item 3: Driver Seat Module (DSM) Installation Note 1. Once the DSM is installed, it is necessary to download the module configuration information from the diagnostic tool into the new module. Page 4569 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until desired positioning is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM's VCT control loop. The PCM will disable the VCT and place the camshaft in a default position if a fault is detected. A related DTC will also be set when this fault 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 cam 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 two halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Page 6472 Relay Box: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 8929 Circuits that go from one diagram to another will be marked with references indicating which diagram the circuit went to/came from, i.e. "See Diagram ##-#". These references will be in the form of unique diagram identification numbers (i.e. 15-3, 70-4, etc). All diagrams are identified with this unique ID number in their captions. Diagrams being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, 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. Introduction To Ford Diagrams 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 diagram 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 which 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 of diagrams. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Electrical - ABS/TCS/Park Brake Lamps Flickering ABS Light: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Service and Repair Front Door Window Regulator: Service and Repair DOOR WINDOW GLASS - FRONT Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. Page 1231 P1565 - P1569: Testing and Inspection P1567 For diagnosis of P1567 refer to chart DTC Index P0500 - P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Cruise Control diagnostic information, See: Cruise Control/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P2065 P2065 - P2069: Testing and Inspection P2065 For diagnosis of code P2065 refer to NOTE 7: NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service Precautions Fuel Pressure Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 3101 Relay Box: Locations Bussed Electrical Center (BEC) Page 5206 ^ Windstar, Freestar, Monterey, Taurus, and Sable with column shifter - Must face to the right rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 1) ^ Taurus and Sable with floor shifter - Must face to the rear of the vehicle with the flat edge of vent base parallel to the chain cover boss (Figure 2) 10. Install one end of a 24" (61 cm) long piece of 5/16" (8 mm) vacuum hose to the 90° vent stem and secure with a small hose clamp. 11. Route the vacuum hose back and up to the cowl area and down next to the brake master cylinder. Carefully tie rap the hose in place next to the brake master cylinder (do not tie rap to brake lines), be sure the end of the hose is facing down and not directly above anything hot. Page 7906 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the RH quarter trim panel. NOTE: Rear parking aid module shown, front and rear parking aid module similar. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 3620 2. Fill the engine cooling system. Page 3642 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 3 Page 3200 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 4072 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Locations Locations View 151-6 Page 4832 3. Disconnect the electrical connector. 4. Remove the screw and lift up to remove the fuel gauge sending unit. INSTALLATION 1. To install, reverse the removal procedure. 2. Turn the ignition key to the ON position to pressurize the fuel system. 3. Visually inspect the fuel system for leaks. Item 22: Fuel Gauge Sending Unit Installation Note 1. Route the fuel gauge sending unit wire through the center of the fuel pump module. 2. NOTE: Both fuel gauge sending unit wires must be routed behind the metal sending unit plate. Page 4505 Oxygen Sensor: Harness Locations View 151-6 Page 4091 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Item 6: Spark Plug Wire-to-Spark Plug Removal Note Page 8303 Part 1 Page 1206 P1515 - P1519: Testing and Inspection P1518 For diagnosis of code P1518 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7462 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Page 7802 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Item 17: Seat Cushion Foam Pad Removal Note Page 7605 Special Tool(s) Brake Pedal Position Switch View 151-11 Page 4418 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 6389 Page 5162 ^ Taurus with floor shifter (Figure 7) 12. Connect the shift cable, if removed. 13. Install the air cleaner cover and outlet pipe. NOTE USE THE ALIGNMENT NOTCHES TO CORRECTLY ALIGN THE AIR CLEANER COVER TO THE AIR CLEANER TRAY. 14. Install the air cleaner housing clamp(s). 15. Connect the air cleaner outlet pipe to the throttle body and tighten to 35 lb-in (4 N.m). 16. Connect the crankcase vent tube to the air cleaner outlet pipe. 17. Connect the MAF sensor electrical connector. 18. Windstar, Freestar, and Monterey only, follow TSB 06-14-10 to seal and install the cowl panel grille. Parts Block OTHER APPLICABLE ARTICLES: 06-14-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061813A 2000-2007 Taurus, 0.5 Hr. 2000-2005 Sable: Replace Transaxle Vent Following Page 4682 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Page 939 P1130 - P1134: Testing and Inspection P1132 For diagnosis of code P1132 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P0297 P0295 - P0299: Testing and Inspection P0297 For diagnosis of code P0297 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 3102 Page 3838 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 4490 Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two design types of IAT sensors used, a stand alone\non-integrated type (Figure 39) and a integrated (Figure 40) 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. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A non-integrated screw in type (Figure 39) and an integrated type, which is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 48). The TMAP sensor consists of a IAT thermistor and a manifold absolute pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation found later. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 2631 1. Remove the OCS. - Feed the OCS components (hose, transducer, wire harness, electronic control unit (ECU) and connectors) through the seat cushion pan opening. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. Part 1 Page 8451 Headliner: Service and Repair HEADLINER REMOVAL 1. If removing the headliner, remove the windshield side garnish mouldings, upper B-pillar, C-pillar and the D-pillar trim panels. 2. If removing the headliner and if equipped, remove the overhead entertainment system. Page 3439 7. Drain the engine oil and refill with clean engine oil. Item 8: Crankshaft Pulley Removal Note 1. Disconnect the RH front anti-lock brake wheel sensor electrical connector. 2. Position a safety stand under the RH side of the subframe. 3. Lower the RH side of the subframe 50.8 mm (2 inch). - Remove the bolts. - Lower the subframe. Page 8502 View 151-19 Page 2645 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Install the driver seat. Do not reactivate the supplemental restraint system as instructed to do so in the seat removal and installation procedure at this time. - After installation, position the driver seat from its forward most position to its rearmost position and then back again. While positioning the seat, make sure that the seat position sensor, bracket or the wire harness do not come in contact with any other part of the seat that may cause damage. 3. Connect the battery ground cable. 4. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Disconnect the battery ground cable and wait at least one minute. 6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 7. Connect the battery ground cable. 8. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Page 1400 P2005 - P2009: Testing and Inspection P2008 For diagnosis of code P2008 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5754 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 [NEW] This supplement to 04S24 involves replacing both front wheel hubs and both front wheel rotors as separate components. The hub and rotor assembly kits that were offered when the Safety Recall was launched are no longer available. SERVICE PROCEDURE [NEW] 1.Replace both front wheel hubs and rotors. Refer to Section 204-00 of the 2004 Freestar/Monterey Workshop Manual found on the PTS website for the latest service procedures. Review the following notes during service: ^ Use new bolts, PN W705696-5436, when installing the new hubs. Tighten to 115 Nm (85 lb-ft). ^ When installing the rotor onto the hub, apply a light coating of High Temperature Nickel Anti-Seize Compound, XL-2, to the mating surfaces of the hub and rotor. DO NOT ALLOW ANY ANTI-SEIZE COMPOUND TO GET ONTO THE STUD BOLT THREADS. Make sure that the compound is free of any debris (dirt, rust, etc.) that could cause an excessive rotor run-out condition. ^ Be sure to reinstall any rotor-to-hub screws that were present during disassembly. Tighten screws to 28 Nm (21 lb-ft). ^ Apply a small patch of Threadlock 262, TA-26, to the last five (5) axle shaft joint threads before installing a new axle shaft nut. Tighten the nut to 130 Nm (96 lb-ft). Page 8959 73III Automotive Meter Page 5868 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: Brake Line-To-HCU Fittings Removal Note 1. Brake lines must be re-installed in the same location as removed. Item 4: HCU Removal Note 1. Remove the Anti-Lock Brake System (ABS) module. For additional information, REFER to Anti-Lock Brake System (ABS) Module. Items 1: Brake Line-To-HCU Fittings Installation Note 1. Bleed the brake system. Page 2180 Brake Switch (Cruise Control): Vehicle Damage Warnings CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Page 4194 The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an Enhanced-Quizzer (E-Quizzer) processor. The primary monitoring function is performed by the Independent Plausibility Check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by specified amount, the IPC takes appropriate mitigating action. ETC System Failure Mode And Effects Management, Part 1 ETC System Failure Mode And Effects Management, Part 2 Since the IPC and main controller share the same processor, they are subject to a number of potential, common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate Failure Mode and Effects Management (FMEM) actions. Electronic Throttle Monitor Operation: Page 9356 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 Page 3395 Page 862 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Driver Page 1628 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 3 Page 5317 Valve Body: Service and Repair Main Control - Pump Special Tool(s) Page 2472 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Air Bag and Safety Belt Pretensioner SRS Seat Belt Tensioner: Description and Operation Air Bag and Safety Belt Pretensioner SRS SAFETY BELT BUCKLE PRETENSIONERS As part of the supplemental restraint system (SRS), the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners rotate to remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a frontal impact event exceeding a programmed limit. Page 9197 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 7063 2. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. 3. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Item 2: Evaporator Core Orifice Installation Note 1. Lubricate the evaporator core orifice O-rings in clean mineral oil and install the evaporator core orifice using the special tool. Page 6635 Item 11: Power Steering Pump Pulley Removal Note 1. Using the special tool, remove the pulley. Item 18 and 14: O-Ring Installation Note 1. Using the special tool, install a new [email protected] seal on the pressure line fitting. Item 11: Power Steering Pump Pulley 1. Using the special tool, install the pulley. Installation Note 1. Using the special tool, install the pulley. Page 4943 Throttle Body: Service and Repair THROTTLE BODY REMOVAL CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or possible damage to the throttle body can occur. 1. Remove the air cleaner outlet pipe. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6515 Disclaimer Page 7589 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Page 5537 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Locations Page 3939 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Page 9103 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 2032 ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 6085 Starter Relay: Testing and Inspection P1100 P1100 - P1104: Testing and Inspection P1100 For diagnosis of code P1100 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service Precautions Heater Core: Service Precautions WARNING: - Carbon monoxide is colorless, odorless and dangerous. If it is necessary to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust collector to vent the exhaust gases outside the closed area. - The heater core inlet hose will become too hot to handle if the system is working correctly. Page 8607 View 151-17 P0602 P0600 - P0604: Testing and Inspection P0602 For diagnosis of code P0602 refer to Note 11: NOTE 11: The Vehicle ID (VID) Block must be reprogrammed. For instructions, refer to the Flash VID Block Procedure. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Page 1397 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1019 P1260 - P1264: Testing and Inspection P1263 OBD II - Base Gasoline For diagnosis of code P1263 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9357 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 86 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0112 refer to the Base Gasoline Diagnostic Chart: P0112-P0147 Forward Crash Sensor Page 7348 The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 2: Utility Compartment Removal Note Page 304 P0215 - P0219: Testing and Inspection P0219 For diagnosis of code P0219 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7043 Illustration 2 Of 3 System Diagnosis P0845 - P0849: Testing and Inspection For diagnosis of code P0846 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 5900 Page 9636 Left Page 8107 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 5210 Service Procedure, Includes Time To Check And Fill Transmission Fluid (Do Not Use With 1 7526A, 17566A, 17508A, 17603A, 9600A, 9601A) 061813B 2004-2007 1.3 Hrs. Freestar/Monterey, 2000-2003 Windstar: Replace Transaxle Vent Following Service Procedure, Includes Time To Remove And Reseal The Cowl Panel Grille, Check And Fill Transmission Fluid (Do Not Use With 17526A, 17566A, 17508A, 17603A, 9600A, 9601A, 061410A) DEALER CODING CONDITION BASIC PART NO. CODE 7L282 41 Disclaimer Page 4282 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7637 Part 2 2. Remove the parts in the order indicated in the illustrations and tables. Item 2: D-ring and Shoulder Height Adjuster Button Cover Removal Note 1. To remove the shoulder height adjuster button cover, squeeze the button and pull the cover from the bottom. Item 9: Seat Side Trim Panel Removal Note 1. To remove the seat side trim panel, remove the two screws. INSTALLATION 1. To install, reverse the removal procedure. Item 10: Safety Belt Anchor Buckle Assembly Bolt Installation Note 1. The anti-rotation tab of the safety belt anchor buckle assembly must be correctly aligned before tightening fasteners for correct installation. Item 9: Seat Side Trim Panel Installation Note 1. Install the seat side trim panel and two screws. Item 2: D-ring and Shoulder Height Adjuster Button Cover Installation Note 1. To install the shoulder height adjuster button cover, squeeze the button and place the bottom of the cover in first. Third Row REAR SAFETY BELT - THIRD ROW Page 4904 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 8794 P1260 P1260 - P1264: Testing and Inspection P1260 For diagnosis of code P1260 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7567 Page 2727 Page 5481 Page 6173 Locations View 151-5 System Diagnosis P0240 - P0244: Testing and Inspection For diagnosis of code P0243 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9514 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 Page 1152 Inspection Page 8088 Trailer Connector: 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. 95-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 324 P0230 - P0234: Testing and Inspection P0234 For diagnosis of code P0234 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5335 Differential Assembly: Testing and Inspection Diagnosis By Symptom (Pinpoint Test) Symptom Chart Symptom Chart Page 7634 Part 3 2. Remove the parts in the order indicated in the illustrations and tables. Item 1: D-ring and Height Adjuster Button Cover Removal Note 1. To remove the height adjuster button cover, squeeze the button and pull the cover from the bottom. Item 8: Seat Side Trim Panel and Recliner Lever Removal Note 1. Using a suitable tool, carefully pry the side shield for access to the recliner handle clip and remove the clip and handle. - Remove the two screws and trim panel. INSTALLATION 1. To install, reverse the removal procedure. Item 11: Safety Belt Buckle Assembly Installation Note 1. The anti-rotation tab must be correctly aligned for correct installation. Item 10: Safety Belt Anchor Buckle Assembly Installation Note Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Page 3765 Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: 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 VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, 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 L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. For Ford L-M technician's, check out the "Programmable Module Installation" link on the Professional Technician Society (PTS) web sight for quick Programmable Module data information by vehicle when using WDS or NGS. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need 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. Page 2971 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Page 3989 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 1056 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3288 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Items 1-3: Rocker Arm Removal Note 1. If the rocker arms are to be reused, they must be installed in their original location. Mark the rocker arms for location before removing. 2. If removing valve springs, rotate the crankshaft until the piston is at the top of its stroke with both the intake and exhaust valves closed prior to removing the rocker arm. Item 7: Valve Tappet Removal Note Page 6330 Page 9293 Headlamp Switch: Service and Repair HEADLAMP SWITCH REMOVAL CAUTION: Cover the end of the tool with tape to prevent damage to the trim panel. NOTE: Use a thin-bladed tool to remove the headlamp switch assembly. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Locations View 151-8 Page 1069 P1275 - P1279: Testing and Inspection P1278 OBD II - Base Gasoline For diagnosis of code P1278 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Service and Repair Lifter / Lash Adjuster: Service and Repair Rocker Arms, Valve Springs, Push Rods, Valve Tappets Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. CAUTION: If components are to be reinstalled, they must be installed in the same position. Mark the components for location. 1. Remove the valve cover. 2. If removing the valve tappets, remove the lower intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 7422 Impact Sensor: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. - The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. - The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Page 2532 Description and Operation Seat Belt Reminder Lamp: Description and Operation SAFETY BELT WARNING SYSTEM - DRIVER SAFETY BELT The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to the ON position, the safety belt warning light illuminates for one to two minutes and the warning chime sounds for four to eight seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, the warning light and warning chime turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for four to eight seconds with no chime. BELT MINDER The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. The passenger safety belt minder feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed set point. To activate or deactivate the belt minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Page 766 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Interior - Glove Box Latch Replacement Glove Compartment Lock: Technical Service Bulletins Interior - Glove Box Latch Replacement TSB 05-2-1 02/07/05 GLOVE BOX LATCH REPLACEMENT FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE If the glove box latch should require service on a 2004-2005 Freestar/Monterey vehicle, a new service part has now been released. ACTION Replace only the glove box latch. The latch can now be serviced separately, it is no longer necessary to replace the entire glove box assembly. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Open the glove box to the maximum position by depressing the two (2) side bumpers. 2. Remove the three (3) screws near the glove box hinge and remove the entire glove box assembly from the instrument panel. 3. Remove the four (4) Phillips head screws "A" that retain the inner glove box bin to the outer door (Figure 1). 4. Disengage the two (2) snaps "B" at the bottom of the bin, these also retain the inner bin to outer door. 5. Remove the three (3) Phillips head screws "C" that hold the latch assembly to the outer door. 6. Replace the latch and reverse the above procedure to reassemble. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050201A 2004-2005 0.3 Hr. Specifications Flex Plate: Specifications Part 2 Of 2 Flexplate bolts ..................................................................................................................................... ................................................ 80 Nm (59 ft. lbs.) Page 6097 Page 1049 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1272 refer to chart Page 807 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6890 Page 5172 ^ Taurus with floor shifter (Figure 7) 12. Connect the shift cable, if removed. 13. Install the air cleaner cover and outlet pipe. NOTE USE THE ALIGNMENT NOTCHES TO CORRECTLY ALIGN THE AIR CLEANER COVER TO THE AIR CLEANER TRAY. 14. Install the air cleaner housing clamp(s). 15. Connect the air cleaner outlet pipe to the throttle body and tighten to 35 lb-in (4 N.m). 16. Connect the crankcase vent tube to the air cleaner outlet pipe. 17. Connect the MAF sensor electrical connector. 18. Windstar, Freestar, and Monterey only, follow TSB 06-14-10 to seal and install the cowl panel grille. Parts Block OTHER APPLICABLE ARTICLES: 06-14-10 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061813A 2000-2007 Taurus, 0.5 Hr. 2000-2005 Sable: Replace Transaxle Vent Following Page 7924 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Removal and Installation Air Bag Control Module: Service and Repair Removal and Installation RESTRAINTS CONTROL MODULE (RCM) Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: - When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Page 9536 Symbols Part 5 Page 1292 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P1711 refer to chart Page 1101 P1380 - P1384: Testing and Inspection P1383 For diagnosis of code P1383 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8299 Page 6453 Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Page 8563 Power Sliding Door Module: Testing and Inspection POWER SLIDING DOOR MODULE SELF-TEST WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. The PSD self-test will attempt to power open and close the PSD. As the PSD is opened and closed, the PSD monitors the system for correct inputs. Upon completing the self-test, DTCs will be logged for any incorrect operations. The PSD also checks the following inputs during a self-test: - overhead console on/off switch circuit - overhead console open/close switch/RKE circuits - B-pillar switch circuit - PARK (enable) circuit from the SJB - vehicle speed circuit from SJB - fuel filler door circuit (left PSD only) The PSD has the ability to reverse the PSD operation if certain conditions exist. This is a normal function of the system, however some electrical concerns may cause the same symptom. If the PSD reverses during operation or during the self-test, always check for an obstruction or misalignment first. If no obstruction or misalignment is found, make sure to complete all DTC and symptom diagnostics. Initialization Procedure If the PSD loses the logic battery supply for any reason, such as battery disconnect, module disconnect or if left open for more than 6 hours, the PSD will lose the PSD position stored in memory. Disconnecting the battery will cause both PSDs to lose PSD position. Disconnecting the PSD connector will only cause the specific module to lose its memory. If only one PSD module is affected, the initialization procedure only needs to be carried out for the specific module. The PSD normal operation will not be restored until the PSD position is once again stored into memory. The initialization procedure is the learning process the PSD uses to restore the PSD position in memory. The PSD monitors the position sensor data received during the initial power open-and-close operation to learn the positions. Refer to Power Sliding Door Initialization. Page 6526 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Page 8079 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 Page 350 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-11 Page 4441 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 561 P0505 - P0509: Testing and Inspection P0507 For diagnosis of code P0507 refer to chart P0505-P0722 NOTE 9: Refer to the Description, Possible Causes and Diagnostic Aids for the DTC in question. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle Service Precautions Fuel Pressure Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 9195 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 1395 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3924 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Page 5997 Diagrams Page 1780 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 2733 Locations View 151-10 Page 1645 Page 6942 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL REMOVAL 1. Lower the glove compartment. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 530 Inspection Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor INTAKE AIR TEMPERATURE SENSOR Typical Stane Alone/Non-integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange Type MAF Sensor The intake air temperature (IAT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Page 9162 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Page 1171 Inspection Page 6434 Trailer Tow Relay, Right Turn Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Right Turn Page 1720 Page 1030 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P1710 P1710 - P1714: Testing and Inspection P1710 For diagnosis of code P1710 refer to chart Part 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9535 Symbols Part 4 Diagrams Accessory Delay Relay 1 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 1 Page 9395 DTC Index B1342 - B2687 Page 3444 5. Install the timing chain, crankshaft gear and camshaft gear as an assembly. 6. Make sure that the timing marks and the keyways are aligned. 7. Remove the retaining pin. 8. Install the synchronizer drive gear. Items 16-10: Engine Front Cover Installation Note 1. CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage. CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage. Page 7643 1. Grasp the belt tongue and pull the belt webbing down to form a loop through the upper (longer and narrower) slot in the tongue. 2. Rotate and fold the belt webbing over itself within the slot to remove the twist. 3. Pull the excess belt webbing back through the upper slot in the belt tongue. 4. Grasp the belt tongue and pull the belt webbing up to form a loop through the lower slot in the tongue. 5. Rotate and fold the belt webbing over itself within the slot to remove the twist. 6. Pull the excess belt webbing through the slot. 7. The safety belt tongue should face inward when completed. Deployed SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED 1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Inoperative SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep fingers and clothing away from moveable Page 2917 DO NOT OVERFILL THE RESERVOIR. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070102A 2004-2007 1.2 Hrs. Freestar/Monterey And 2003 Windstar: Replace The Power Steering Return Hose Includes Time To Flush The Power Steering System (Do Not Use With 3713AC, 3697A) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 07 Disclaimer Page 1070 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1278 refer to chart Page 1207 Inspection Page 2002 Page 9051 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 7332 Page 1061 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1275 refer to chart Page 9503 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Output Shaft Speed (OSS) Sensor Page 1338 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 663 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0713 refer to chart Page 7890 Keyless Entry Key-Pad: Description and Operation Keyless Entry Keypad The keyless entry keypad, located on the exterior of the driver door, provides a method for the customer to access their vehicle without a key or remote transmitter. The keyless entry keypad feature: locks all doors and liftgate while arming the perimeter alarm (if equipped). - unlocks only the driver door and disarms the perimeter alarm (if equipped). - unlocks all doors and liftgate. - programs/erases customer key code. - enables/disables autolocking. - opens/closes power sliding doors (if equipped). The keyless entry keypad feature operates independently of key position status, vehicle speed, or transmission position. When a keyless entry keypad button is pressed, the keyless entry keypad buttons illuminate to provide better visibility. If LOCK ALL DOORS is entered, or 5 seconds have elapsed since the last button press, the illumination is turned off. Each vehicle equipped with a keyless entry keypad is programmed with a 5-digit factory keyless entry keypad code. This code is provided to the customer through a wallet card in the owner literature package. In addition, this code is available through a diagnostic tool and is also printed on the SJB label. A personal keyless entry keypad code can be programmed into the SJB. When entering codes, each digit must be entered within 5 seconds of the prior digit. Anti-scan Feature If the wrong code has been entered 7 times (35 consecutive button presses), the keyless entry keypad will go into an anti-scan mode. This mode disables the keyless entry keypad for 1 minute and the keyless entry keypad lamp will flash. The anti-scan feature will turn off after: 1 minute of keyless entry keypad inactivity. - pressing the UNLOCK button on the remote transmitter. - the key is turned to the ON position. Unlocking the Doors and Liftgate with the Keyless Entry Keypad To unlock the driver door, enter either the factory set code or the personal code (each digit must be pressed within 5 seconds of the prior digit). The interior lamps will illuminate. To unlock all doors, enter either the factory set code or the personal code (driver door unlocks) and press the 3/4 control within 5 seconds. Opening and Closing the Sliding Doors with the Keyless Entry Keypad To open or close the sliding door, enter either the factory set code or the personal code (each digit must be pressed within 5 seconds of the prior digit) then press the 5/6 button for the driver side door or 9/0 for the passenger side door. Locking the Doors with the Keyless Entry Keypad It is not necessary to enter the factory set or personal code prior to locking all doors. To lock all doors, press the 7/8 and 9/0 controls at the same time. Central Locking/Unlocking The central locking/unlocking function is independent of the ignition switch and transmission range selector lever position. Central unlocking of all the doors is accomplished with: driver or passenger door lock control switches (unless the unlock inhibit feature is enabled). - two unlock commands from the remote transmitter within 3 seconds. - keyless entry keypad. Central locking of all doors is accomplished with: door lock control switches - lock command from the remote transmitter - keyless entry keypad (if equipped) When the vehicle is in an armed or full-alarm security state, any unlock command from the door lock control switches will be ignored if the unlock inhibit feature is enabled. The door lock control switches will be enabled if a valid unlock command has been received from the remote transmitter, keyless entry keypad, or the key is cycled to ON. Smart Junction Box (SJB) Additional Features The SJB can also be programmed to enable/disable the following features: perimeter lighting feature - unlock inhibit feature Perimeter Lighting Programming Page 6976 Disclaimer Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Page 8099 Symbols Part 2 Gap Spark Plug: Specifications Gap Spark Plug Gap.................................................................................................................................... ...................................... 1.3-1.4 mm (0.052-0.056 in) Page 1854 Fuel Pump Relay: Testing and Inspection Page 6140 Page 6341 Page 6161 Page 218 Inspection Locations View 151-5 Page 5789 FSA VIN LIST ACTIVATED? Yes Available through the website. Owner names and addresses were available by September 27, 2004. NOTE: 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 action. 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 owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer 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 Field Service Action. 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. 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. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S24 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION Page 1046 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1271 refer to chart Page 2757 located in the instrument cluster. The LTW system must be reset when tire replacement, maintenance, system repair is performed or any time tire pressure is adjusted. To reset the system, press and hold the "Tire Reset" switch for a minimum of three seconds. The LTW warning lamp will flash 3 times, indicating a reset has been initiated. If the lamp illuminates, reset the tire pressure to specification before resetting the system. If the problem persists go to the Symptom Chart. The LTW system is not capable of detecting rapid loss of inflation. The system may not detect loss of inflation in more than one tire. The LTW system can be deactivated. Page 5710 127-2 Page 7258 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 9210 SJB C2280d SJB C2280h Stoplamp Switch C278 Test F PINPOINT TEST F: THE STOPLAMPS ARE INOPERATIVE P0703 P0700 - P0704: Testing and Inspection P0703 Engine Related Diagnosis For diagnosis of code P0703 refer to chart P0505-P0722 NOTE 15: REFER to Exterior Lighting component testing in Lighting and Horns for further diagnosis of the lighting control module LCM system. Make sure the brake pedal was applied and released for the KOER self-test and the brake pedal was applied for the KOEO self-test. See: Lighting and Page 3467 Item 7: Air Cleaner Cover Installation Note 1. NOTE: No tools are needed to install the air cleaner cover. Installation should be carried out using hands only. Use the alignment notches to correctly align the air cleaner cover to the air cleaner tray. Page 3083 Locations Page 3049 Page 8081 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 Page 2849 Item 7: Air Cleaner Cover Installation Note 1. NOTE: No tools are needed to install the air cleaner cover. Installation should be carried out using hands only. Use the alignment notches to correctly align the air cleaner cover to the air cleaner tray. Page 5503 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 133 P0107-P0193 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4476 Page 2287 Page 370 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3222 Compression Check: Testing and Inspection Compression Test-Compression Gauge Check 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 such as the Compression Tester 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 five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Part 1 0f 2 Part 2 Of 2 Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Page 9349 Symbols Part 4 Page 2982 approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses. - Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. 1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves. 2. Verify that the valves on the fluorescent dye injector are closed. 3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye. 4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set. 5. Open all valves and inject the fluorescent dye into the refrigerant system. 6. When fluorescent dye injection is complete, close all valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set. Fluorescent Dye Injection - Using a Dye Injector Loop Kit NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. - Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses. - Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C. Page 1915 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) is mounted on the center tunnel under the instrument panel. The RCM carries out the following functions: supplies current flow to the inflators to deploy the air bags in the event of a deployable crash. - supplies current flow to the inflators to deploy the safety canopies in the event of a deployable crash. - activates the safety belt retractor pretensioners to remove slack from the safety belt. - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the lamp fault code (LFC) detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). - signals the instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. - contains an internal safing sensor which is not serviced separately. - records deployment event data. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the LFC. The air bag indicator will flash the LFC three times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the (DLC), using a scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient current to deploy the front air bags and safety belt pretensioners in the event that the ignition circuit is damaged or lost in a collision before the RCM determines that air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Page 2761 11. CAUTION: Do not drill deeper than 9.6 mm (0.37 inch) into the shock tower. Drill three 3.2 mm (0.12 inch) holes through the alignment plate and shock tower. ^ Clean and paint any exposed metal. 12. Install three pop rivets. ^ Use 3.2 mm (0.12 inch) diameter x 6.4 mm (0.25 inch) grip range steel pop rivets. 13. Install the cowl top vent panel. Page 451 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4139 Page 3647 Locations View 151-18 Page 5704 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 7803 1. CAUTION: - Use care when separating the seat cushion trim cover from the hook and loop strip. The hook and loop strip can be torn from the seat cushion foam. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. If installing an OCS service kit or installing a new seat cushion trim cover, remove the hog rings and separate the trim cover from the foam pad. After removing the hog rings, reach a hand between the trim cover and foam pad and carefully separate the hook and loop strips. Item 22: Pressure Sensor Removal Note 1. Using a suitable tool, pry the bracket tab, releasing the pressure sensor. Separate the pressure sensor from the seat cushion pan and disconnect the electrical connector. Item 24: Occupant Classification Sensor (OCS) Removal Note 1. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. Page 7593 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 2582 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION Page 6312 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Page 9097 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 3814 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Page 9688 2. If removing the right quarter window glass, disconnect the electrical connector. 3. Separate the window latch. 4. Remove the nuts and the rear quarter window glass. INSTALLATION 1. To install, reverse the removal procedure. Item 3: Rear Quarter Window Glass Assembly Installation Note 1. If reinstalling the original quarter glass, clean off any remaining butyl prior to installation of the quarter window glass. 2. Clean the area of any remaining residue prior to installation of the quarter window glass. Page 6903 View 151-11 Page 3700 Throttle Plate Controller Check Operation The purpose of the TPPC is to control the throttle position to the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle signal. The TPPC interprets the duty cycle signal as follows: 0% <= DC < 5% - Out of range, limp home default position. - 5% <= DC < 6% - Commanded default position, closed. - 6% <= DC < 7% - Commanded default position. Used for key-on, engine off. - 7% <= DC < 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - 10% <= DC <= 92% - Normal operation, between 0 degrees (hard-stop) and 82%, 10% duty cycle = 0 degrees throttle angle, 92% duty cycle = 82 degrees throttle angle. - 92% < DC <= 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - 96% < DC <= 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate to be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The "H" driver is capable of positive or negative voltage to the Electronic Throttle Body Motor. Page 6005 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 6970 Disclaimer P1740 P1740 - P1744: Testing and Inspection P1740 4R70W For diagnosis of code P1740 refer to chart Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6243 Page 7255 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Page 5775 FSA VIN LIST ACTIVATED? Yes Available through the website. Owner names and addresses were available by September 27, 2004. NOTE: 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 action. 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 owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer 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 Field Service Action. 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. 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. OWNER REFUNDS ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 6251, Dearborn, MI 48121-6251. ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close the recall on the vehicle. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 04S24 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION Service Precautions Memory Positioning Module: Service Precautions CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Page 1877 Page 5676 11. Tighten the RH front disc brake caliper bleeder screw. For additional information, refer to Specifications. 12. Repeat Steps 8, 9, 10 and 11 for the LH front disc brake caliper bleeder screw. Pressure WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Do not allow the master cylinder to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 1. Clean all the dirt from the area and remove the brake master cylinder filler cap. Fill the brake master cylinder reservoir with the 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: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Page 9370 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 5644 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Park/Turn Lamp, Left Front Page 8248 3. Position the door window glass halfway down to gain access to the door window glass rivets. - Remove the rivets. Item 4: Rivet Removal Removal Note 1. Remove the rivets. Item 5: Front Door Window Regulator Removal Note 1. Disconnect the electrical connector. 2. WARNING: Prior to power window motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. Failure to place the regulator arms in a fixed position can cause the spring to suddenly release resulting in personal injury. NOTE: The counterbalance spring assists the window in the upward direction. Remove the bolts and the window regulator motor. Item 4: Rivet Installation Note 1. Using the special tool, install the rivets. Item 1: Rivet Installation Note 1. Using the special tool, install the rivets. Page 3229 1. If the valve tappets are to be reused, they must be installed in their original location. Mark the valve tappets for location before removing. Items 8-11: Valve Spring Removal Note 1. CAUTION: The piston must be at the top of its stroke with both the intake and exhaust valves closed prior to removing the valve spring. CAUTION: If a valve drops into the cylinder, remove the cylinder head. Hold the valve in the cylinder head. Remove the spark plug. - Apply a minimum of 689 kPa (100 psi) of compressed air into the cylinder. 2. Using the special tool, compress the valve springs. 3. Remove the following: 1. Valve spring retainer key 2. Valve spring retainer 3. Valve spring 4. Valve stem seal Item 8: Valve Spring Retainer Key Installation Note 1. CAUTION: Do not release the compressed air from the cylinder until after the valve spring keys are installed. After installing the valve spring keys, release the air pressure from the cylinder. Install the spark plug. Items 3-1: Rocker Arm Installation Note ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 5278 Vehicles with Trailer Towing Package The transaxle fluid cooling system consists of: ^ a non-repairable integral fluid cooler located in the RH radiator tank ^ an Oil-To-Air (OTA) fluid cooler A portion of the OTA fluid cooler also cools the power steering fluid. ^ a fluid cooler inlet tube assembly ^ a fluid cooler outlet tube ^ a tube assembly ^ retaining clips ^ fluid cooler hoses ^ hose clamps The transmission fluid flows from the transaxle, through the fluid cooler inlet tube assembly, through the integral fluid cooler, through the fluid cooler outlet tube, through the OTA fluid cooler, and then returns to the transaxle through the tube assembly. For fluid cooler flow testing, and backflushing and cleaning procedures, refer to Transmission Fluid Cooler - Backflushing and Cleaning. Page 3570 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 5 Initial Inspection and Diagnostic Overview Parking Lamp: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart 2. Visually inspect for obvious signs of mechanical or electrical damage. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. NOTE: Make sure the headlamp switch is in the OFF position. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. - check the ignition switch position. 5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual. 6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: - SCP, ISO or UBP circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for SJB, refer to Information Bus (Module Communications Network). - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the SJB. 7. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index. See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Page 659 Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 9397 Parking Lamp: Pinpoint Tests BEC C1035c LH Auxiliary Lamp C1445, RH Auxiliary Lamp C1446 Page 6042 Battery: Pinpoint Tests PINPOINT TEST H: BATTERY CONDITION TEST Test H1 Normal Operation Battery condition is determined by measuring battery terminal voltage after a specific discharge current is applied for a specified time period. Possible Causes - battery charge - battery Auxiliary Relay Box Page 6493 Page 256 Inspection Page 3857 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Page 4868 P0980 P0980 - P0984: Testing and Inspection P0980 For diagnosis of code P0980 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 1749 Page 7717 Seat Belt Tensioner: Service and Repair Safety Belt Pretensioner Disposal - Undeployed Inoperative SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, INOPERATIVE WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Carry a live safety belt retractor pretensioner or safety belt buckle pretensioner so as to keep fingers and clothing away from moveable parts. This will reduce the risk of injury in the event of an accidental deployment. NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and safety belt retractor pretensioners must be treated the same as any inoperative live safety belt buckle pretensioner or safety belt retractor pretensioner being returned. 1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company. Scrapped Vehicle SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE REMOTE DEPLOYMENT WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the safety belt pretensioner is deployed, hearing protection is required. - Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. All vehicles 1. Remove the safety belt buckle pretensioner assembly from the vehicle. Safety belt buckle pretensioner without a hard-wired electrical connector 2. Cut and remove the safety belt buckle pretensioner electrical connector from the main seat wire harness, leaving about four inches of extra wire. 3. Attach the electrical connector to the safety belt buckle pretensioner. All vehicles 4. Strip the wires near the electrical connector. Page 62 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4144 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 7351 Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Page 6930 Auxiliary Blower Motor Resistor Page 6261 Note: The bussed electrical center is located in the engine compartment. Page 9318 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 295 P0210 - P0214: Testing and Inspection P0211 For diagnosis of code P0211 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Page 1962 Page 9000 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Page 8680 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 1572 View 151-17 Page 3722 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Safety Belt System Seat Belt Tension Sensor: Description and Operation Safety Belt System SAFETY BELT TENSION SENSOR The safety belt tension sensor is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is located at the front passenger safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Page 5283 7. Inspect the transmission fluid cooler fitting threads for damage. ^ If the threads are damaged, install a new radiator. ^ If the threads show no sign of damage, proceed to the next step. 8. CAUTION: Thread sealant or tape should never be used on the threads of the transmission fluid cooler fittings. The use of such materials will create a leak path. Install a new O-ring on the transmission fluid cooler fitting. 9. NOTE: Do not use air tools to tighten the transmission fluid cooler fitting. Use a hand-operated torque wrench only. Making sure that the gasket between the transmission fluid cooler and the inside of the radiator tank is still in place, install the transmission fluid cooler fitting. 10. Follow the procedure to install a new O-ring on the other transmission fluid cooler fitting. 11. Make sure that no radiator coolant has entered the transmission fluid cooler. Install the radiator in the vehicle. 12. Verify that both the transmission and the engine cooling system are at the correct fluid levels. Output Shaft Speed (OSS) Sensor Page 8710 View 151-13 Page 7208 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL REMOVAL 1. Lower the glove compartment. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9332 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 4069 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Technician Safety Information Battery: Technician Safety Information WARNING: - Do not attempt the Battery Drain test on a lead-acid battery that has recently been recharged. Explosive gases may cause personal injury. Failure to follow these instructions may result in personal injury. - Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before repairing, installing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect any auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury. - Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury. Page 9676 Front Door Window Glass: Service and Repair DOOR WINDOW GLASS - FRONT Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. Page 4762 Fuel Injector Wiring Harness: Service and Repair FUEL CHARGING WIRING HARNESS REMOVAL WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Disconnect the battery ground cable. 2. Remove the upper intake manifold. 3. Remove the parts in the order indicated in the illustration and table. Item 5: Fuel Charging Wiring Harness Removal Note Page 7749 View 151-29 Page 1238 P1570 - P1574: Testing and Inspection Cruise Control Related Diagnosis For diagnosis of code P1572, refer to chart: P0500-P0703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Cruise Control system, follow this link: See: Cruise Control/Testing and Inspection Intake Air Temperature Sensor Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor INTAKE AIR TEMPERATURE SENSOR Typical Stane Alone/Non-integrated Intake Air Temperature (IAT) Sensors Typical Integrated Intake Air Temperature (IAT) Sensor Incorporated Into A Drop-in Or Flange Type MAF Sensor The intake air temperature (IAT) sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Page 7623 Seat Belt: Description and Operation FASTENING SAFETY BELTS WARNING: Do not introduce slack into the safety belt system because the belt locks upon impact where it is positioned. Use the shoulder safety belt on the outside shoulder only. Never wear the shoulder safety belt under the arm. Never swing the shoulder safety belt around the neck over the inside shoulder. Never use a single belt for more than one person. Make sure the lap portion of the belt is fitted snugly and as low as possible around the hips, not the waist. Failure to follow these precautions could increase the chance and severity of injury in a collision. Always follow the preceding safety precautions when fastening the safety belts. Page 9665 Page 3413 Clean and inspect the engine block and front cover as follows: - Pack the exposed portion of the oil pan with clean shop towels. - Plug the oil and coolant passages. - Clean the gasket surfaces. - Clean all surfaces requiring gasket sealant with metal surface cleaner. - Using compressed air, remove any remaining foreign material from the engine block and front cover. - Remove the shop towels from the oil pan. - Remove the plugs or seals from the oil and coolant passages. 2. Apply a small amount of silicone gasket and sealant as shown. 3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown. Timing Cover Torque Sequence 4. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence. NOTE: Use pipe sealant with tenon on studs No. 4, 6 and bolt No. 12. Install the engine front cover with the engine front cover studs in their original locations. ABS - Module Replacement Service Tip Electronic Brake Control Module: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 7053 Evaporator Core: Description and Operation Auxiliary Climate Control EVAPORATOR CORE NOTE: The auxiliary evaporator core is not separately serviceable. It is serviced only with the auxiliary climate control housing. The auxiliary climate control system uses a rear evaporator core which operates in the same manner as the front evaporator core. Page 5947 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Removal and Installation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. CAUTION: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if exposed to these charges. NOTE: When installing a new ABS module, it must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration and calibration procedures. For module configuration and calibration, refer to Module Communications Network. 1. Remove the HCU. For additional information, refer to Hydraulic Control Unit (HCU). 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Locations Page 1219 Inspection ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 9510 Symbols Part 5 Page 5006 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS) Three Different Types Of Crankshaft Position (CKP) Sensors The crankshaft position (CKP) sensor is a magnetic transducer mounted on the engine block or timing cover and is 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 powertrain control module (PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9 degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP 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 fixed reference (Figure 31). Page 3416 Item 5: Oil Filter Installation Note 1. Tighten oil filter one half turn after gasket makes contact with oil filter housing. Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Page 3069 Fuse Block: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 7972 Disclaimer Page 8546 INSTALLATION 1. To install, reverse the removal procedure. Item 3: Driver Seat Module (DSM) Installation Note 1. Once the DSM is installed, it is necessary to download the module configuration information from the diagnostic tool into the new module. Page 9405 Test P4-P5 Normal Operation The SJB monitors the headlamp switch position. When the headlamp switch is in the parking lamps ON position, the SJB supplies voltage to the parking and license lamps. If a problem is detected with any of the signal circuits to the headlamp switch, the SJB will default the parking lamps and headlamps ON. The LH front parking/turn lamp and side marker are supplied voltage from circuit 1340 (DG). The RH front parking/turn lamp and side marker are supplied voltage from circuit 1339 (BK/PK). The LH auxiliary parking lamp is supplied voltage from circuit 1344 (VT/LB). The RH signal mirror is supplied voltage from circuit 1343 (PK/OG). The LH rear lamp is supplied voltage from circuit 1364 (DB/YE). The RH rear turn lamp is supplied voltage from circuit 1366 (TN/RD). The license lamps are supplied voltage from circuit 1370 (DG/LG). Possible Causes - circuit 1339 (BK/PK) short to power - circuit 1340 (DG) short to power - circuit 1343 (PK/OG) short to power - circuit 1344 (VT/LB) short to power - circuit 1364 (DB/YE) short to power - circuit 1366 (TN/RD) short to power - circuit 1370 (DG/LG) short to power - headlamp switch - SJB Page 4599 4. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps. Item 6: Evaporative Emission Canister Cover Removal Note 1. Remove the pin-type retainers and evaporative emission canister cover. INSTALLATION 1. To install, reverse the removal procedure. 2. Carry out a leak test. See: Testing and Inspection/Component Tests and General Diagnostics/Evaporative Emission System Leak Test 3. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Component Tests and General Page 7340 Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 7600 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Page 6374 Page 7604 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Service and Repair Thermostat Bypass Hose: Service and Repair REMOVAL AND INSTALLATION Bypass Tube Material Material 1. Drain the cooling system. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. 4. Fill and bleed the cooling system. Page 6318 6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt splice (Figure 8). 7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool handles to open, then remove crimped butt splice. 8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool around. 9. Check for acceptable crimp. a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly off center, but not off the end of the buff splice (Figure 9-a). b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of buff splice (Figure 9-b). c. Wire is visible through inspection hole of splices (Figure 9-c). 10. Evenly position heat shrink tubing over wire repair (Figure 5). NOTE OVERLAP TUBING ON BOTH WIRES. 11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the solder point (Figure 5). Gap Spark Plug: Specifications Gap Spark Plug Gap.................................................................................................................................... ...................................... 1.3-1.4 mm (0.052-0.056 in) Page 1955 Page 8654 Part 2 2. Disassemble the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 4: Recliner Handle Clip Disassembly Note 1. Using a suitable tool, carefully pry the side shield for access to the recliner handle clip and remove the clip. Item 13: Backrest-to-Seat Track Bolts Disassembly Note 1. Removal of cushion release cables. Page 449 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2726 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Page 1434 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7100 Heater Hose: Service and Repair Removal and Installation AUXILIARY HEATER OUTLET AND INLET LINE REMOVAL 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. NOTE: A portion of the coolant remaining in the auxiliary heater outlet and inlet lines, and the heater core, will drain from the auxiliary heater outlet and inlet line connections when disconnected. Clamp off and disconnect the heater hoses at the front of the auxiliary heater inlet and outlet lines. 3. Remove the bolt and the front line bracket. 4. Remove the bolts and the two rear line brackets. Left Front Page 4901 Disclaimer ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 850 P0975 - P0979: Testing and Inspection P0976 For diagnosis of code P0976 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 3088 Page 9347 Symbols Part 2 Page 2799 3. If removing the ignition coil, remove the wiper motor and pivot assembly. 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Page 6084 Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Page 6393 Page 940 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: All Technical Service Bulletins Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Harness: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 4697 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 4176 Data Link Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 761 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0758 refer to chart Page 4885 Main Relay (Computer/Fuel System): Testing and Inspection Page 8678 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 9746 4. Remove the parts in the order indicated in the illustration and table. Item 3: Windshield Washer Reservoir Bolts Removal Note Page 9708 9. Remove the dual lock windshield glass stop adhesive backing. 10. Apply urethane glass primer to the same area that was prepped in the previous step. Allow five minutes to dry. 11. Cut the urethane adhesive applicator tip to specification. 12. Apply a bead of urethane adhesive to the pinch weld. 13. CAUTION: Open the windows to prevent the windshield glass from being pushed out by air pressure if a door is closed. Install the windshield glass on the pinch weld. Align the windshield glass to the body using the alignment marks while pushing downward to set the stops. 14. Inspect the windshield glass installation for air or water leaks and add urethane adhesive where needed. 15. Place 2 strips of duct tape onto the windshield glass and secure it to the roof panel. This will help avoid misalignment while the urethane cures. Page 3529 Part 1 Of 4 Part 2 Of 4 Part 3 Of 4 Page 77 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0108 refer to chart P0230 P0230 - P0234: Testing and Inspection P0230 For diagnosis of code P0230 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Main Climate Control Evaporator Core: Description and Operation Main Climate Control EVAPORATOR CORE NOTE: - If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. The evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the evaporator core through the evaporator core inlet tube, continues over to the remaining five plate/fin sections, and then moves out of the evaporator core through the evaporator core outlet tube. - This flow pattern accelerates the flow of refrigerant and oil through the evaporator core. Page 5693 Symbols Part 3 Page 8447 Freestar/Monterey: Replace Glove Box Latch DEALER CODING CONDITION BASIC PART NO. CODE 1706072 07 Disclaimer Page 5626 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 3593 1. Disconnect the fluid cooler tubes from the connector assembly. ^ Push the fluid cooler tube inward slightly, squeeze the retaining clip, and with a slight twisting motion, pull the fluid cooler tube out of the connector assembly. Item 15: Radiator Support Bolts Removal Note 1. Detach the power steering lines from both sides of the radiator lower support. 2. Remove the bolt and position the A C muffler bracket aside. Item 19: Radiator Removal Note 1. Lower the vehicle, cut the mechanic's wire and remove the radiator, cooling fans and shroud as an assembly. Page 5037 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 9323 Symbols Part 5 Page 1787 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 2091 Page 3376 Item 3: Crankshaft Rear Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation. Assemble the special tools and the crankshaft rear seal. 3. Install the special tools on the rear of the crankshaft. 4. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the engine block. Page 6401 Page 3387 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Item 3: Subframe Bolt Removal Note Rear View 151-26 Page 4884 Page 7392 Special Tool(s) Page 8616 Page 1849 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) REMOVAL 1. Remove the LH lower B-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8713 View 151-20 Page 270 P0200 - P0204: Testing and Inspection P0204 OBD II - Base Gasoline For diagnosis of code P0204 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 4170 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 9132 Fuel Pump Module (For Returnable Fuel Systems) Page 8080 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 780 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3110 Page 6214 Description and Operation Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING SYSTEM Overview Variable Cam Timing (VCT) enables rotation of the camshaft(s) relative to the crankshaft (phase-shafting) as a function of engine operating conditions. There are four 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 four operational modes; idle, part throttle, wide open throttle and default mode. At idle and low engine speeds with closed throttle, the phase angle are controlled by air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM controls cam timing 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 improve torque. In addition, on some applications a VCT system can eliminated the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Currently for the 2004 model year, Ford Motor Company uses the PS and DEPS systems. The IPS system is on Lincoln LS, Thunderbird and Focus SVT and the DEPS system is on the F150 5.4L 3V. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (camshaft position sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (crankshaft position sensor) provides the PCM with crankshaft positioning information in 10 degree increments (Figure 115). 1. The PCM receives input signals from the IAT (intake air temperature), ECT (engine coolant temperature), EOT (engine oil temperature), CMP, TP (throttle position), MAF (mass air flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper 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 Page 2456 Locations View 151-6 Page 7267 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Page 6135 Page 1098 Inspection Page 2258 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module (Figure 71),(Figure 72) and(Figure 73) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Specifications Crankshaft: Specifications Main bearing journal diameter-1, 2, 3 ................................................................................................................. 63.978-63.998 mm (2.5188-2.5196 inch) Main bearing journal maximum taper; 0.016 mm D or 0.008 mm R between any two measurement points Main bearing journal maximum out-of-round; 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.016 mm (inch) TOTAL Main bearing journal-to-cylinder block clearance-desired; 0.025-0.035 mm (0.001-0.0014 inch) Main bearing journal-to-cylinder block clearance-allowable; 0.013-0.058 mm (0.0005-0.0023 inch) Connecting rod journal diameter ............................................................................................................................... 58.682-58.702 mm (2.310-2.311 inch) Connecting rod journal maximum taper; 0.016 mm D or 0.008 mm R between any two measurement points Connecting rod journal maximum out-of-round; 0.008 mm (0.0003 inch) MAX in 45 degrees, 0.016 mm (0.006 inch) Total Crankshaft maximum end play .......................................................................................................................................... 0.10-0.20 mm (0.004-0.008 inch) Page 1532 Page 747 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0753 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 152 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4349 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 2636 6. NOTE: When installing an occupant classification sensor service kit, the main seat wire harness pressure sensor electrical connector does not get used. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. 2 Slide the electronic control unit (ECU) into the seat cushion pan bracket. The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). 3 Install the rivets. 4 Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector. 5 Tie-strap the unused main seat wire harness pressure sensor electrical connector safely out of the way. 6 Tie-strap all loose wire harnesses and electrical connectors safely out of the way. Item 4: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 7: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 8: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Page 6244 Page 8674 Seat Heater: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 1565 Page 528 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7665 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 8160 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 Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Page 2569 Page 2579 Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The left side is shown, the right side is similar. - The first row side impact sensors are located under the seat beneath the carpet. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Service and Repair Air Cleaner Housing: Service and Repair AIR CLEANER ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Air Cleaner Cover Removal Note 1. NOTE: No tools are needed to remove the air cleaner cover. Removal should be carried out using hands only. Release the clamps and separate the air cleaner cover from the air cleaner tray. INSTALLATION 1. To install, reverse the removal procedure. Page 1741 Page 8112 Trailer Lamps: 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. 95-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 4208 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 4186 Data Link Connector: 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 Page 6594 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 7738 b. D_ABAG2 "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST'. d. D_PRTNR "DRVR PRETENSIONER CKT RES". e. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". f. P_ABAGR "PSGR AIRBAG RESISTANCE". g. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". h. P_ABAG2 "PSGR SIDE AIRBAG RESISTANCE ND CNT". i. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14B321 28 Disclaimer Page 6454 Page 3531 2. Install the special tools to the exhaust manifold. 3. Attach engine lifting equipment and raise the engine 127 mm (5 inches). Items 20, 19 and 18: Coolant Pump-to-Engine Front Cover Nuts and Bolts Installation Note Water Pump Torque Sequence 1. Install the water pump with a new gasket. ^ Tighten the nuts and bolts in the sequence shown. Page 2756 Thrust Angle ^ Rear thrust angle can be defined as a line bisecting rear toe or simply, the direction in which the rear wheels are pointed. ^ Rear thrust angle = (LR toe minus RR toe) / 2 ^ If the rear wheels are pointed to the right, thrust angle is positive; if the rear wheels are pointed to the left, thrust angle is negative. 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. Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. Shimmy Shimmy, as observed 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 observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering is used to describe 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 hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, 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). Efforts 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 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 roadability problem, it is important to understand the difference between wander and poor groove feel. Low Tire Warning (LTW) System The Low Tire Warning (LTW) system detects differences in inflation pressures in one or more tires. The system uses the ABS wheel speed sensors to monitor the rolling radius of the wheel and tire assemblies. If a difference in rolling radius is detected, the ABS module illuminates the LTW lamp Page 6891 Ambient Temperature Sensor / Switch HVAC: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL Ambient Temperature Sensor The ambient temperature sensor signal is received by the smart junction box (SJB) which communicates it to the EATC module via the vehicles SCP network. Page 7370 Air Bag Resistor: Description and Operation SEAT SIDE AIR BAG BRIDGE RESISTOR NOTE: Do not deactivate the seat side air bag circuit by removing the bridge resistor from the electrical connector. If the seat side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the seat side air bag electrical connector, a low-resistance fault will be generated. The seat side air bag bridge resistor is located on the seat riser pedestal crossmember under the front seats. SAFETY CANOPY BRIDGE RESISTOR NOTE: Do not deactivate the safety canopy module circuit by removing the bridge resistor from the electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low-resistance fault will be generated. The safety canopy bridge resistor: is equipped on vehicles without safety canopy modules. - must not be removed in the deactivation procedure. - is mounted behind the headliner in the rear of the vehicle at the rear tailgate opening. Page 1037 P1265 - P1269: Testing and Inspection P1268 OBD II - Base Gasoline For diagnosis of code P1268 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6043 Battery: Component Tests and General Diagnostics BATTERY - DRAIN TESTING WARNING: Do not attempt this test on a lead-acid battery that has recently been recharged. Explosive gases may cause personal injury. Failure to follow these instructions may result in personal injury. CAUTION: To prevent damage to the meter, do not crank the engine or operate accessories that draw more than 10A. NOTE: - No factory-equipped vehicle should have more than a 50 mA (0.050 amp) draw. - Many electronic modules draw 10 mA (0.010 amp) or more continuously. - Use an in-line ammeter between the negative battery post and its respective cable. - Typically, a drain of approximately one amp is attributed to an engine compartment lamp, glove compartment lamp, or interior lamp staying on continually. Other component failures or wiring shorts are located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is found, the meter reading will fall to an acceptable level. If the drain is still not located after checking all the fuses, it is due to the generator. - To accurately test the drain on a battery, an in-line ammeter must be used. Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules. Check for current drains on the battery in excess of 50 milliamps (0.050 amp) with all the electrical accessories off and the vehicle at rest for at least 40 minutes. Current drains can be tested with the following procedure: 1. Make sure the bussed electrical center (BEC) and central junction box (CJB) are accessible without turning on the interior lights or the underhood lights. 2. Drive the vehicle at least five minutes and over 48 km/h (30 mph) to turn on and activate the vehicle systems. 3. Allow the vehicle to sit with the key off for at least 40 minutes to allow modules to time out/power down. 4. Connect a fused jumper wire (30A) between the negative battery cable and the negative battery post to prevent modules from resetting and to catch capacitive drains. 5. Disconnect the negative battery cable from the negative battery post without breaking the connection of the jumper wire. 6. NOTE: It is very important that continuity is not broken between the battery and the negative battery cable when connecting the meter. If this happens, the entire procedure must be repeated. Connect the battery tester between the negative battery cable and the post. The meter must be capable of reading milliamps and should have a 10 amp capability. 7. NOTE: - If the meter settings need to be switched or the test leads need to be moved to another jack, the jumper wire must be reinstalled to avoid breaking continuity. - Amperage draw will vary from vehicle to vehicle depending on the equipment package. Compare to a similar vehicle for reference. - No factory-equipped vehicle should have more than a 50 mA (0.050 amp) draw. Remove the jumper wire. 8. Note the amperage draw. Draw will vary from vehicle to vehicle depending on the equipment package. Compare to a similar vehicle for reference. No factory-equipped vehicle should have more than a 50 mA draw (0.050 amp). 9. If the draw is found to be excessive, remove the fuses from the CJB one at a time and note the current reading. Do not reinstall fuses until you have finished testing. To correctly isolate each of the circuits, all of the fuses may need to be removed and install one fuse, note the amperage draw, then remove the fuse and install the next fuse, etc. 10. If the current draw is still excessive, remove the fuses from the BEC one at a time and note the current drop. Do not reinstall the fuses until you have finished testing. To correctly isolate each of the circuits, all of the fuses may need to be removed and install one fuse, note the amperage draw, then remove the fuse and install the next fuse, etc. When the current level drops to an acceptable level after removing a fuse, the circuit containing the excessive draw has been located. 11. Check the wiring diagrams for any circuits that run from the battery without passing through the BEC or the CJB. If the current draw is still excessive, disconnect these circuits until the draw is found. Also disconnect the generator electrical connections if the draw can not be located. The generator may be internally shorted, causing the current drain. Page 311 P0220 - P0224: Testing and Inspection P0222 For diagnosis of code P0222 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Description and Operation Fuel Pump Signal: Description and Operation FUEL PUMP MONITOR Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The Fuel Pump Monitor (FPM) circuit is spliced into the fuel pump power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed and there is a B+ supply to the fuel pump relay. Fuel Pump Driver Module Applications Fuel Pump Driver Module Duty Cycle Signals The fuel pump driver module (FPDM) communicates diagnostic information to the powertrain control module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table. Interior - Leather Wrapping On Steering Wheel Is Loose Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose TSB 07-4-3 03/05/07 LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty 2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape Hybrid 2007 Edge 2004-2007 F-650, F-750 LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007 MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 04-24-3 to update the vehicle model years. ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area. ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL. CAUTION AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE. Page 5641 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 8086 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 4089 Spark Plug: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Locations View 151-18 Page 7203 View 151-12 Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 2328 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 2584 (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 831 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7978 Garage Door Opener Transmitter: Description and Operation UNIVERSAL TRANSMITTER The HomeLink(R) universal transmitter is an integral part of the LH sun visor assembly. This universal transmitter provides a convenient way to substitute up to three hand-held transmitters with a single built-in device. The transmitter will learn the radio frequency codes of most current transmitters to operate garage doors, entry gates, security systems, and home or office lighting. Page 7818 4. WARNING: Do not separate components. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): - select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 4970 DEALER CODING CONDITION BASIC PART NO. CODE 9F955 33 Disclaimer Page 9604 Gasoline Fuel System Fuel Pressure Sensor/Switch: Description and Operation Gasoline Fuel System FUEL RAIL PRESSURE SENSOR Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 36) is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and decreases as pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Fuel Rai Pressure (FRP) Sensor The fuel rail pressure (FRP) sensor (Figure 37) senses the pressure difference between the fuel rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel system. The differential fuel/intake manifold pressure together with measured fuel temperature provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserve 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. Locations P0040 P0040 - P0044: Testing and Inspection P0040 For diagnosis of code P0040 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6695 Special Tool(s) Page 2523 Page 51 P0060 - P0064: Testing and Inspection P0061 For diagnosis of code P0061 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5036 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 6174 Locations View 151-6 Page 7266 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 9383 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 Page 3516 Spark Plug: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 2701 Items 9 and 10: Digital TR Sensor and Retaining Bolts Installation Note 1. Install the digital TR sensor and loosely install the bolts. 2. Using the special tool, align the digital TR sensor. Recall - Front Hub & Rotor Replacement Technical Service Bulletin # 04S24S1 Date: 060322 Attachment I - Administrative Information OASIS ACTIVATED? Yes. OASIS was activated on September 2, 2004 A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair TSB 04-24-5 12/13/04 REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria, Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005 Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape 2004-2005 F-150, Freestar 2005 Escape Hybrid LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego 1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner This article supersedes TSB 04-18-9 to update vehicle applications and service procedure. ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass. ACTION Follow the diagnostic and repair procedures included in this article to inspect and service rear defroster grid lines, integral antenna concerns or broken terminal tabs. SERVICE PROCEDURE Warrantable/Non Warrantable repairs Warrantable grid line repairs typically can be identified by one inoperative grid line with a small discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are scratched or have the silver material removed are not warrantable and should be addressed with the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated Back Lite Damageability Job Aid for additional information and examples of defects and damage. NOTE THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON Service Precautions Fuel Pressure Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Locations Page 1659 Page 1832 Engine Control Module: Service and Repair Flash Electrically Eraseable Programmable Read Only Memory FLASH ELECTRICALLY ERASEABLE PROGRAMMABLE READ ONLY MEMORY - FLASH EEPROM Description Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an Integrated Circuit (IC) internal to the PCM. The EEPROM contains the vehicle strategy including calibration information specific to the vehicle and is capable of being reprogrammed or reflashed repeatedly. As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM as described under Programming the VID Block for a Replacement PCM. Failure to perform this procedure may generate fault codes: P1635, P1639, VID Block not programmed or is corrupt. The VID block in an existing PCM can also be tailored to accommodate various hardware/parameter changes made to the vehicle since production. Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of Acceptable Range is one of the main causes for code: 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 VIN number, octane adjust, fuel octane, fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle hardware and supported by the VID block will be displayed on the scan tool. When changing items in the VID block, the strategy will place range limits on certain items such as tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When this limit is reached, the scan tool will display a message indicating the need to flash the PCM again to reset the VID block. Each of the procedures described below use the Worldwide Diagnostic System (WDS). Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the manufacturers users manual for details. Programming the VID Block for a Replacement PCM A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are two procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM. Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced. Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute Module/Parameter reprogramming referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile = 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, 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 L-M technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for "AS Built" data. Non Ford technicians, use the Fed World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or "Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required. For Ford L-M technician's, check out the "Programmable Module Installation" link on the Professional Technician Society (PTS) web sight for quick Programmable Module data information by vehicle when using WDS or NGS. Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM will need 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. Page 284 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2517 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 6752 Part 1 Of 3 Part 2 Of 3 Trailer Tow Relay, Right Turn Page 9603 Heated Glass Element Relay: Testing and Inspection Page 688 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0721 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3698 The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an Enhanced-Quizzer (E-Quizzer) processor. The primary monitoring function is performed by the Independent Plausibility Check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by specified amount, the IPC takes appropriate mitigating action. ETC System Failure Mode And Effects Management, Part 1 ETC System Failure Mode And Effects Management, Part 2 Since the IPC and main controller share the same processor, they are subject to a number of potential, common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate Failure Mode and Effects Management (FMEM) actions. Electronic Throttle Monitor Operation: Page 968 Inspection Page 2031 Page 6503 P0221 P0220 - P0224: Testing and Inspection P0221 For diagnosis of code P0221 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4557 Page 4434 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Service and Repair Engine Block Heater: Service and Repair Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the parts in the order indicated in the illustration and table. 4. To install, reverse the removal procedure. 5. Fill and bleed the cooling system. Item 2: Block Heater Retaining Screw Removal Note 1. CAUTION: Do not loosen the block heater retaining screw more than necessary. Loosen the block heater retaining screw. Item 3: Block Heater Installation Note 1. Clean and inspect the engine block mating surface before installing the block heater. Lubricate the block heater seal and the cylinder block hole with clean engine coolant to ease installation. Page 870 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 206 Inspection Page 2559 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Seat Adjust Switch, Driver Side Front View 151-16 Page 7770 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. Page 3787 Fuel Pump Relay: Testing and Inspection Specifications Crankshaft Main Bearing: Specifications Main bearing bore inside diameter ......................................................................................................... 68.905 mm (2.713 inch)-68.885 mm (2.712 inch) Main Bearing Caps Bolts Stage 1 ................................................................................................................................................ .................................................. 50 Nm (37 ft. lbs.) Stage 2 ................................................................ .......................................................................................................... Rotate an additional 120 degrees. Description and Operation Evaporative Vapor Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The fuel tank pressure (FTP) sensor (Figure 103) or inline fuel tank pressure (FTP) sensor (Figure 104) is used to measure the fuel tank pressure during the EVAP Leak Check Monitor. Page 4384 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 8428 16. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Disconnect the passenger seat side air bag module electrical connector. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 18. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. All vehicles 19. Disconnect the passenger seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the passenger seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat safety belt buckle pretensioner electrical connector. Page 5307 View 151-6 Page 5625 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 7800 Part 1 Page 1526 Description and Operation Transmission Cooler: Description and Operation Transaxle Cooling Vehicles without Trailer Towing Package The transaxle fluid cooling system consists of ^ a non-repairable integral fluid cooler located in the RH radiator tank ^ a fluid cooler inlet tube assembly ^ a fluid cooler outlet tube assembly ^ retaining clips The transmission fluid flows from the transaxle, through the fluid cooler inlet tube assembly, through the integral fluid cooler, and returns to the transaxle through the fluid cooler outlet tube assembly. For fluid cooler flow testing, and backflushing and cleaning procedures, refer to Transmission Fluid Cooler - Backflushing and Cleaning. See: Service and Repair/Transmission Fluid Cooler - Backflushing and Cleaning Page 9437 Specifications Compressor Clutch: Specifications Magnetic Clutch Air gap between pulley and clutch plate..................................................................................................................................0.35-0.75 mm (0.014-0.030 in) Page 6350 Fuse Block: Locations Bussed Electrical Center (BEC) Page 8276 Power Sliding Door Module: Service Precautions WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. Page 294 Inspection Page 3748 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 8645 Part 2 4. Disassemble the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Recliner Handle Disassembly Note 1. Release the recliner handle cover tab and remove the handle. 2. Remove the side shield screw from behind the recliner handle. Item 10: Seat Side Air Bag Connector Disassembly Note 1. Disconnect and detach the seat side air bag connector and route through the seat cushion frame for backrest removal, noting the route for installation. Page 45 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 431 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations View 151-15 Page 863 P0980 - P0984: Testing and Inspection P0981 For diagnosis of code P0981 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3721 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 8640 Part 2 4. Disassemble the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Recliner Handle Cover Disassembly Note Page 1476 P2195 - P2199: Testing and Inspection P2196 OBD II - Base Gasoline For diagnosis of code P2196 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P2196 refer to chart Diagrams Page 255 P0195 - P0199: Testing and Inspection P0198 For diagnosis of code P0198 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9402 Test O5-O7 Page 3008 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Page 6605 Page 9011 View 151-22 Page 6439 Page 5983 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Page 7027 The A/C refrigerant line peanut fittings are sometimes used in place of spring lock couplings or tube-O fittings. - The male and female blocks of the peanut fitting are retained with a nut. - An O-ring seal is installed around the tube on the male block. - Support the female fitting with a wrench to prevent twisting of the tubes. - When correctly assembled the male and female fittings should be flush. TUBE O-FITTING Tube O-Fitting When disconnecting or connecting tube O-fittings, observe the following. - The male and female portions of the fitting are retained with a nut. - Support the female fitting with a wrench to prevent twisting of the tubes when disconnecting. - An O-ring seal is installed around the tube on the male side of the fitting. - Use only the O-ring seal listed in the Ford Master Parts Catalog. Locations P1245 P1245 - P1249: Testing and Inspection P1245 For diagnosis of code P1245 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 161 Inspection Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Locations View 151-2 Power Window Switch, RH Side Front Page 3567 ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Service Precautions Fuel Temperature Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 2941 DO NOT OVERFILL THE RESERVOIR. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 070102A 2004-2007 1.2 Hrs. Freestar/Monterey And 2003 Windstar: Replace The Power Steering Return Hose Includes Time To Flush The Power Steering System (Do Not Use With 3713AC, 3697A) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 07 Disclaimer Service Precautions Fuel Temperature Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 8979 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Page 5231 3. Remove the parts in the order indicated in the following illustration and table. 4. To install, reverse the removal procedure. Item 1: LH Metal Seal Protector Removal Note 1. NOTE: The differential seal is a two-piece construction. Using the special tool, remove left differential seal. Page 4574 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Page 1995 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR REMOVAL 1. Remove the front or rear bumper cover. 2. NOTE: Rear parking aid sensor shown, front parking aid sensor similar. Remove the parts in the order indicated in the illustration and table. Item 2: Parking Aid Sensor Removal Note 1. Release the tabs and remove the parking aid sensor. INSTALLATION 1. To install, reverse the removal procedure. Page 5661 Page 6679 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Specifications Firing Order: Specifications 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 switch1 causing the magnetic field to collapse inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Coil packs come in 6-tower, 6-tower horizontal and series 5 6-tower models (Freestar/Monterey/F 150 Heritage 3.9/4.2L). 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. 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. Page 3571 ABS - Module Replacement Service Tip Yaw Rate Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 6176 Page 5557 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 9715 Page 3038 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 8452 Part 1 Locations View 151-13 Page 6403 Temperature Blend Door Actuator Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator RH TEMPERATURE BLEND DOOR ACTUATOR - RH REMOVAL NOTE: The RH temperature blend door actuator can be accessed from below the RH side of the instrument panel. 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. LH TEMPERATURE BLEND DOOR ACTUATOR - LH REMOVAL NOTE: The LH temperature blend door actuator can be accessed from below the LH side of the instrument panel. Page 8585 3. Make sure the cover passes over the pad lips as shown in (Figure 1). NOTE THE VEHICLE'S ROOF RACK MAY OR MAY NOT HAVE CROSS BARS. CROSS BARS ARE AN OPTION THAT CAN BE ORDERED FOR THE 2004 MODEL YEAR. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Disclaimer Page 6842 Part 1 Of 3 Part 2 Of 3 Page 1440 P2105 - P2109: Testing and Inspection P2106 For diagnosis of code P2106 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1948 Heated Glass Element Relay: Testing and Inspection Page 1296 P1710 - P1714: Testing and Inspection P1713 4R70W For diagnosis of code P1713 refer to chart Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1170 P1475 - P1479: Testing and Inspection P1479 For diagnosis of code P1479 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations P0411 P0410 - P0414: Testing and Inspection P0411 For diagnosis of code P0411 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9217 Test H5-H7 Normal Operation The stoplamp switch is supplied voltage from the SJB through circuit 10 (LG/RD). When the brake pedal is applied, the stoplamp switch routes voltage to circuit 810 (LG/RD) back to the SJB. Circuit 810 (LG/RD) is then routed out of the SJB to the brake shift interlock solenoid.The SJB monitors voltage input from the stoplamp switch. When the SJB senses brake pedal application, the SJB then sends voltage to the rear lamps. Voltage for the LH and RH stoplamps is supplied through circuits 1363 (WH/RD) and 1365 (GY/LB) respectively. Voltage for the high mounted stoplamp is supplied through circuit 1456 (RD/LB). Ground for the stoplamps is provided through circuit 1205 (BK). Possible Causes - circuit 810 (LG/RD) short to power - circuit 1363 (WH/RD) short to power - circuit 1365 (GY/LB) short to power - circuit 1456 (RD/LB) short to power - stoplamp switch - brake shift interlock solenoid - SJB Page 1879 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 1263 P1650 - P1654: Testing and Inspection P1651 For diagnosis of code P1651 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 7042 Illustration 1 Of 3 Page 2064 System Diagnosis P1295 - P1299: Testing and Inspection For diagnosis of code P1299 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 678 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P2005 P2005 - P2009: Testing and Inspection P2005 For diagnosis of code P2005 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1447 P2110 - P2114: Testing and Inspection P2111 For diagnosis of code P2111 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module Page 778 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4386 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 3764 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Removal and Installation POWERTRAIN CONTROL MODULE (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5366 Item 1: Front Axle Wheel Hub Retainer Installation Note 1. CAUTION: Install and tighten the new axle wheel hub retainer to specification in a continuous rotation. Stopping the rotation during installation will cause the nylon lock to set incorrectly. This will cause incorrect torque readings while tightening the retainer and lead to bearing failure. Always install a new retainer after loosening the retainer or when the retainer has not been installed to specification in a continuous rotation. CAUTION: Never use power tools to tighten the axle wheel hub retainer. NOTE: Apply a small patch of sealant to the last five outboard CV joint threads. Install a new axle wheel hub retainer. ^ Remove the steel rod from the brake disc. Page 7765 Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. Remove the front seat on the side with the affected side impact sensor. 4. Position the carpet aside to access the front row side impact sensor. 5. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 3035 Reactivation WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is still disconnected before proceeding with the reactivation portion of this procedure. All vehicles 1. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 2. Connect the driver seat safety belt buckle pretensioner electrical connector. 1 Connect the driver seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 3. Remove the restraint system diagnostic tool from the vehicle harness side of the driver seat side air bag module electrical connector. Page 3407 7. Drain the engine oil and refill with clean engine oil. Item 8: Crankshaft Pulley Removal Note 1. Disconnect the RH front anti-lock brake wheel sensor electrical connector. 2. Position a safety stand under the RH side of the subframe. 3. Lower the RH side of the subframe 50.8 mm (2 inch). - Remove the bolts. - Lower the subframe. Page 4395 View 151-4 Page 7877 Page 893 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7316 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 851 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5628 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 5200 Service Procedure, Includes Time To Check And Fill Transmission Fluid (Do Not Use With 1 7526A, 17566A, 17508A, 17603A, 9600A, 9601A) 061813B 2004-2007 1.3 Hrs. Freestar/Monterey, 2000-2003 Windstar: Replace Transaxle Vent Following Service Procedure, Includes Time To Remove And Reseal The Cowl Panel Grille, Check And Fill Transmission Fluid (Do Not Use With 17526A, 17566A, 17508A, 17603A, 9600A, 9601A, 061410A) DEALER CODING CONDITION BASIC PART NO. CODE 7L282 41 Disclaimer Page 2720 Page 2218 Blower Motor Switch: Service and Repair BLOWER MOTOR SPEED CONTROL REMOVAL 1. Lower the glove compartment. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Locations View 151-10 P0276 P0275 - P0279: Testing and Inspection P0276 For diagnosis of code P0276 refer to chart B1219-B1317 / P0182-P1272 Locations View 151-18 Page 7984 Garage Door Opener Transmitter: Service and Repair UNIVERSAL TRANSMITTER PROGRAMMING WARNING: A garage door opening system that cannot stop or reverse itself after detecting an object in its path does not meet current federal safety standards. To decrease the risk of serious injury or death, do not use this HomeLink(R) universal transmitter with a door opening system that lacks stop and reverse features as required by federal standards. This includes any garage door opening system manufactured before April 1, 1982. 1. Verify the hand-held transmitter is operative. 2. Prepare for programming the universal transmitter, erase all three channels by holding down the two outside buttons until the red light begins to flash (20-30 seconds). Release both buttons. 3. Select one of the three universal transmitter channels to be programmed by pressing the desired button. 4. Hold the end of the hand-held transmitter 25-51 mm (1-2 inches) from the front surface of the universal transmitter so that the red light can still be seen. 5. NOTE: For Canadian vehicles only: during programming, the hand-held transmitter may automatically stop transmitting after two seconds, which may not be long enough to program the universal transmitter. If programming this type of hand-held transmitter, continue to hold the button on the universal transmitter while re-pressing the hand-held transmitter button every two seconds. Use both hands to press the hand-held transmitter button and the desired button on the universal transmitter. Do not release either button. 6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and then rapidly. Release both buttons when the rapid flashing begins. The universal transmitter has successfully learned the new frequency signal and can be used in place of the hand-held transmitter(s). 7. NOTE: A code protected or rolling code garage door opener may require further programming. To operate, simply press the appropriate button on the universal transmitter. The red light is on while the signal is being transmitted. Training a Garage Door Opener Equipped With Rolling Codes 1. Program the hand-held transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the universal transmitter. 1 Remove the cover panel from the garage door opener receiver. 2 Locate the training button on the garage door opener receiver. Location and color of the button may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual or owner literature. 3 Press the training button on the garage door opener receiver for 1-2 seconds. 4 Press the programmed universal transmitter button for as long as the universal transmitter red light flashes (1-2 seconds). Release the button and re-press the button to confirm that the universal transmitter is trained to the receiver. 5 The garage door opener should recognize the universal transmitter. Page 955 P1150 - P1154: Testing and Inspection P1152 For diagnosis of code P1152 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2744 Wiper Switch: Diagrams Page 7020 Control Module HVAC: Diagrams Electronic Manual Temperature Control (EMTC) Module Page 172 Inspection Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 9506 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 5289 Transmission Cooler: Service and Repair Transmission Fluid Cooler Transmission Fluid Cooler Special Tool(s) Material Removal and Installation NOTE: Vehicles that are not equipped with a trailer tow package will have this type of a cooling system. 1. With the vehicle in NEUTRAL, position it on a hoist. Page 5071 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Page 8307 Heavy Duty Riveter Page 4771 Fuel Pressure Regulator: Description and Operation Natural Gas Fuel System FUEL PRESSURE REGULATOR Fuel Pressure Regulator The fuel pressure regulator (Figure 82) used in the Natural Gas fuel system is a single-stage pressure reducing regulator which expands natural gas from storage pressures of 1,379 to 20,685 kPa (200 to 3,000 psig) to engine fuel injector pressures of 724 to 862 kPa (105 to 125 psig). The regulator contains a pressure relief device, a 1,896 kPa (275 psig) check valve, which protects the low pressure fuel system. The low pressure fuel system no longer must fulfill the design requirements of the high pressure fuel system, therefore reducing cost, weight and complexity. When gas expands, the fuel temperature drops significantly causing extreme cold temperatures (-177°C or -160°F) that may damage synthetic fuel system components as well as cause water vapor within the fuel to condense, freeze and plug the lines, valve and injectors. To prevent this, engine coolant is routed through the fuel pressure regulator to warm the fuel before it expands. The regulator has an internal thermostat in its coolant bowl to control the flow of engine coolant. This prevents overheating and subsequent thinning of the fuel which may cause lean combustion. Outlet coolant flow is restricted by the thermostat when it rises above approximately 82°C (100°F). If service of the coolant bowl and/or thermostat is required, the coolant bowl and thermostat are serviced separately. Page 8239 View 151-19 Page 660 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0712 refer to chart Part 3 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 2524 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 1698 Specifications Engine Oil Pressure: Specifications Oil Pressure (Hot 2,500 rpm) ............................................................................................................... ................................................................. 40-125 psi Page 2371 Page 7635 1. The anti-rotation tab must be correctly aligned for correct installation. Item 8: Seat Side Trim Panel and Recliner Lever Installation Note 1. Install the seat side trim panel, two screws and recliner lever. Item 1: D-ring and Height Adjuster Button Cover Installation Note 1. To install the height adjuster button cover, squeeze the button and place the bottom of the cover in first. Bucket Seat REAR SAFETY BELT - BUCKET SEAT, SECOND ROW Torx Bit, Safety Belt Bolt SPECIAL TOOL(S) REMOVAL WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters (if so equipped) child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. NOTE: Lower rear quarter trim removed for clarity. Right side shown, left side similar. 1. To access the second row outboard safety belt retractor, remove the quarter trim panel. Page 5944 View 151-14 Page 6477 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Locations View 151-2 Page 7261 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery and wait at least one minute. 2. Open the steering wheel access door. 3. Release the tab and slide the connector off. Page 2174 View 151-13 Page 4988 Firing order........................................................................................................................................... ..................................................................1-4-2-5-3-6 Page 1932 Auxiliary Blower Motor Relay ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 4316 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. Item 2: HO2S and Catalyst Monitor Sensors Removal Note Page 5281 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart Page 2811 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Technician Safety Information Fuel Rail: Technician Safety Information WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Locations View 151-5 Page 6167 Locations Number One Cylinder: Locations Page 760 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0758 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Locations View 151-10 Page 1120 Inspection Page 3999 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 7039 Evaporator Case: Description and Operation HEATER CORE AND EVAPORATOR CORE HOUSING The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Page 2358 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 5804 Brake Rotor/Disc: Service and Repair Brake Disc Machining Special Tool(s) Special Tool(s) CAUTION: Do not use a bench lathe to machine the brake discs. NOTE: Read the entire operating manual and view the video shipped with the lathe before installing, operating, or repairing the lathe. NOTE: If the thickness of the brake disc is less than the minimum thickness to machine specification, install a new brake disc. This will make sure that the brake disc will be above minimum thickness 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. 1. NOTE: It is not necessary to disconnect the brake line from the brake caliper. Position the brake caliper and brake caliper anchor bracket aside. For additional information, refer to Front Disc Brake or Rear Disc Brake. 2. For vehicles with a 2-piece brake disc and hub assembly: 1 Mark the brake disc and the wheel stud for correct indexing during re-assembly. 2 Remove the brake disc from the hub. 3 CAUTION: Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout. Remove corrosion from the wheel mounting surface, both disc mounting surfaces, and hub mounting surface. 4 Align the match marks and install the brake disc on the hub. 3. Machine the brake disc using an on-car brake lathe. 1 Install the hub adapter and silencer belt, if necessary. 2 Install the cutting lathe. 3 If lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.000 mm (0.000 inch), maximum is 0.08 mm (0.003 inch). 4 Center the cutting head, adjust the cutting bits, and install the chip deflector. 5 NOTE: The depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008 inch). 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. 6 Remove the lathe and, if installed, the silencer belt. 7 Remove the hub adapter. 4. Remove metal shavings. 5. For vehicles with a 2-piece brake disc and hub assembly: 1 Remove the brake disc from the hub. 2 Remove metal shavings from the hub, the brake disc mounting surfaces and from the ABS sensors. 3 Apply anti-seize lubricant to hub mounting surface to prevent corrosion. 4 Align the match marks and install the brake disc on the hub. 6. NOTE: It is not required to install new brake pads if friction material properties are within guidelines. Refer to Brake Pads. Install the brake caliper and brake caliper anchor bracket. For additional information, refer to Front Disc Brake or Rear Disc Brake. Page 7386 Part 2 6. NOTE: If the clockspring is to be reinstalled, do not allow the clockspring to turn from its removal position. Remove the parts in the order indicated in the illustration and table. Item 1: Screw Removal Note 1. Pull out at the top of the trim panel, releasing the clips and pivot the panel down. Item 7: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder. 1 Turn the ignition lock cylinder to the RUN position. 2 While pushing in on the tab, pull out on the ignition lock cylinder removing it. Item 12: Tape Removal Note 1. If installing the same clockspring, apply two strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. Item 14: Connectors Removal Note Locations View 151-28 Forward Crash Sensor View 151-1 Page 3745 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 2130 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Page 5905 Vacuum Brake Booster: Testing and Inspection Brake Booster 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several times to exhaust all vacuum in the system. 3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the brake booster system is not functioning. Continue with the following steps. 4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is available to the brake booster, connect the vacuum booster hose to the brake booster check valve and repeat Steps 2 and 3. 5. If no downward movement of the brake pedal is felt, install a new brake booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. 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 the brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information, refer to Brake System Bleeding. Page 4550 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Page 97 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4903 Page 472 P0400 - P0404: Testing and Inspection P0403 For diagnosis of code P0403 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2421 View 151-4 Output Shaft Speed Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed Sensor OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (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 generated. Page 6133 Page 145 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3908 Page 575 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6260 Page 4862 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH REMOVAL 1. Remove the jack access cover on the RH side interior rear quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. P0972 P0970 - P0974: Testing and Inspection P0972 For diagnosis of code P0972 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: Customer Interest Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 4950 1. Remove the cable separator clip. 2. Squeeze the tabs and remove the accelerator cable from the bracket. 3. Remove the accelerator cable from the accelerator cable clips on the LH shock tower and the air cleaner housing. Item 3: Accelerator Cable-to-Pedal Removal Note 1. Remove the accelerator cable from the rubber plunger. Page 9611 TIME TO MATCH THE REST OF THE GRID. 5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step outside and inspect the repaired area. If the repair compound is visible above or below the grid, the excess can be removed. This may be done by placing a single-edge razor blade on the back window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better but may not be cosmetically appealing. CAUTION BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID LINES FUNCTION PROPERLY WHEN FINISHED. Curing The service coating will air-dry in approximately one (1) minute and the system can be energized after five minutes. Maximum hardness and adhesion occur after approximately 24 hours. SOLDER METHOD OF LEAD TERMINAL NOTE THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE. PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY. The new terminal will cover the original terminal location, but must be placed so that the new terminal conductive areas will be placed on a good conductive base. This area should be cleaned with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to improve appearance. CAUTION DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER. BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL. The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a visual indication when the terminal has reached the proper temperature to melt the solder on the terminal. When the proper temperature is achieved the temperature paint will liquefy and change color. Page 9055 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 3309 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by replacing the suspect drive belt with a known good O.E.M. drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. NOTE: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Replacement drive belts, other than O.E.M., may track differently/incorrectly. If a replacement drive belt tracks incorrectly, a new drive belt should be installed with an O.E.M. drive belt to avoid performance failure or loss of drive belt during cold operation. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension, chirp, and squeal noises. If the above procedures do not correct the drive belt noise, try installing a drive belt with a known good O.E.M. drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Page 3436 Timing Cover: Service and Repair Engine Front Cover, Timing Gears, Chain and Tensioners Special Tools And Equipment Special Tool(s) Material Material Page 8918 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 7337 Air Bag Control Module: Locations View 151-8 Page 4806 Fuel Pump Relay: Testing and Inspection Page 5851 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 7048 1. Remove the five screws and the floor duct. 2. Remove the seven screws and the heater core cover. - Detach the wire harness. 3. Remove the heater core. Item 17: Evaporator Core Removal Note 1. Remove the eleven screws and the evaporator core cover. 2. Remove the dash panel seal and the evaporator core. Item 18: Air Inlet Duct Removal Note 1. Remove the air inlet duct. 1 Disconnect the air inlet mode door actuator electrical connector. 2 Remove the four screws and the air inlet duct. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Fill the engine coolant level. 4. Evacuate, leak test and charge the refrigerant system. Page 6843 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Page 4589 4-cylinder engine, so only the Bank 1 HO2S(s) will be utilized. Catalytic Converter A catalyst is a material that remains unchanged when it initiates and increases the speed of a chemical reaction. A catalyst will also enable 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 475 to 575°F (246 to 301°C). A fast light catalyst is a three way catalyst (TWC) that is located as close to the exhaust manifold as possible. Because the light off catalyst is located close too the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights off, the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency TWC Conversion Efficiency Chart A TWC requires a stoichiometric fuel ratio, 14.7 pounds of air to 1 pound of fuel (14.7:1), for high conversion efficiency. In order to achieve these high efficiencies, the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency (Figure 123). For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NOx conversion efficiency. Exhaust System Page 9128 Description and Operation Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING SYSTEM Overview Variable Cam Timing (VCT) enables rotation of the camshaft(s) relative to the crankshaft (phase-shafting) as a function of engine operating conditions. There are four 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 four operational modes; idle, part throttle, wide open throttle and default mode. At idle and low engine speeds with closed throttle, the phase angle are controlled by air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM controls cam timing 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 improve torque. In addition, on some applications a VCT system can eliminated the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Currently for the 2004 model year, Ford Motor Company uses the PS and DEPS systems. The IPS system is on Lincoln LS, Thunderbird and Focus SVT and the DEPS system is on the F150 5.4L 3V. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (camshaft position sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (crankshaft position sensor) provides the PCM with crankshaft positioning information in 10 degree increments (Figure 115). 1. The PCM receives input signals from the IAT (intake air temperature), ECT (engine coolant temperature), EOT (engine oil temperature), CMP, TP (throttle position), MAF (mass air flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper 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 Page 5536 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Locations View 151-5 Page 7150 4. Fill the dye/lubricant injector with the correct amount of clean 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. Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Page 2789 Firing Order: Locations Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 7536 Page 5812 Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Page 3223 Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two 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 percent of the highest reading. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Pulley and Crankshaft Seal Special Tools And Equipment Special Tool(s) Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the accessory drive belt. Page 1827 P0660 P0660 - P0664: Testing and Inspection P0660 For diagnosis of code P0660 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9706 6. Remove the parts in the order indicated in the illustration and table. Item 1: Windshield Glass Removal Note 1. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. 2. CAUTION: - Cover the instrument panel in order to prevent possible damage. - Care must be used to avoid scratching the pinch weld. - If equipped, care must be taken to avoid damage to the headliner wiring harness. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting - When cutting foam inside, first cut foam dam to access the urethane adhesive. Using the special tool, starting at the top center of the windshield glass, cut the urethane adhesive away from the glass and work down the sides. Left Front Technician Safety Information Windshield Washer Reservoir: Technician Safety Information WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Page 3903 View 151-5 Locations View 151-11 Page 2495 Fuel Pressure Sensor/Switch: Description and Operation Natural Gas Fuel System INJECTION PRESSURE SENSOR Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 414 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2430 1. Using the special tool, remove the HO2S and the catalyst monitor sensors. INSTALLATION 1. To install, reverse the removal procedure. Item 2: HO2S and Catalyst Monitor Sensors Installation Note 1. NOTE: Apply a light coat of anti-seize lubricant to the threads of the HO2S and the catalyst monitor sensors. Using the special tool, install the HO2S and the catalyst monitor sensors. ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 8938 Symbols Part 5 Testing and Inspection Mini ISO Relay: Testing and Inspection Page 7263 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. Page 8949 Cigarette Lighter: 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. 44-1 Brakes - Accelerated rear Brake Pad Wear Brake Pad: All Technical Service Bulletins Brakes - Accelerated rear Brake Pad Wear TSB 04-26-10 12/31/04 REAR BRAKE LINING ACCELERATED WEAR FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit accelerated rear brake pad lining wear, heavily scored rear rotors, or metal pickup in the rear lining. ACTION Replace the rear brake pad linings, machine the rotors as required. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042610A 2004-2005 0.7 Hr. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads Only 042610B 2004-2005 1.6 Hrs. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads, Machine Both Rear Brake Rotors On Vehicle DEALER CODING CONDITION BASIC PART NO. CODE 2200 42 Disclaimer Service Precautions Memory Positioning Module: Service Precautions CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Page 6741 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Reference Diagram ............................................................................................................................. ............................................................................. D Page 3808 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 703 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0732 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 1182 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7468 1. Remove the OCS. - Feed the OCS components (hose, transducer, wire harness, electronic control unit (ECU) and connectors) through the seat cushion pan opening. INSTALLATION WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes at the beginning of the removal procedure. Part 1 Page 3856 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Page 1823 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 1543 Memory Positioning Module: Service and Repair DRIVER SEAT MODULE (DSM) REMOVAL 1. CAUTION: - Prior to the removal of the module, it is necessary to upload module configuration information to the appropriate diagnostic equipment. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery. 2. Remove the driver seat. 3. Remove the parts in the order indicated in the illustration and table. Description and Operation Seat Belt Reminder Buzzer: Description and Operation SAFETY BELT WARNING SYSTEM - DRIVER SAFETY BELT The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to the ON position, the safety belt warning light illuminates for one to two minutes and the warning chime sounds for four to eight seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, the warning light and warning chime turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for four to eight seconds with no chime. BELT MINDER The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. The passenger safety belt minder feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed set point. To activate or deactivate the belt minder feature, refer to Instrument Panel, Gauges and Warning Indicators. System Diagnosis P1450 - P1454: Testing and Inspection For diagnosis of code P1451 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8790 Page 1020 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1263 refer to chart Page 5092 Spark Plug: Service and Repair IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. If removing the ignition coil, remove the wiper motor and pivot assembly. Page 7674 5. NOTE: If the two bolts on the height adjuster are not stripped, refer to Front Safety Belt or Rear Safety Belt-Bench Seat, Second Row, Rear Safety Belt-Bucket Seat, Second Row. If the bolts are stripped, replace the height adjuster. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit several times to seat the insert keys. Page 9721 Page 6451 Page 6704 Disclaimer Page 8596 Restraints - Control Module DTCs & Associated Fault PIDs Seat Belt Control Module: Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Electronic Manual Temperature Control Air Door Actuator / Motor: Description and Operation Electronic Manual Temperature Control TEMPERATURE BLEND DOOR ACTUATOR(S) The temperature blend door actuator(s): - is located on the heater core and evaporator core housing. - moves the temperature blend door(s) on command from the EMTC module. - contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend door. - applies a 5 volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EMTC module and is matched with an expected wiper voltage value. The EMTC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EMTC module wiper voltage value. MODE DOOR ACTUATORS The two mode door actuators: - include the air inlet door and defrost/panel/floor mode door actuators. - direct system airflow to the vehicle interior as determined by the climate control assembly. - contains a reversible electric motor - (defrost/panel/floor mode door actuator only) contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door. - (defrost/panel/floor mode door actuator only) apply a 5 volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EMTC module and is matched with an expected wiper voltage value. The EMTC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EMTC module wiper voltage value. Locations View 151-18 Page 7338 View 151-14 System Diagnosis P0815 - P0819: Testing and Inspection For diagnosis of code P0815 refer to chart P0815-P1780 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7595 28. Disconnect the driver seat side air bag module electrical connector. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 29. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 30. Disconnect the driver seat safety belt buckle pretensioner electrical connector. 1 Slide and disengage the driver seat safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat safety belt buckle pretensioner electrical connector. 31. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat safety belt buckle pretensioner electrical connector. 32. Connect the battery. 33. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Prove Out Procedure 34. Disconnect the battery and wait at least one minute. Page 8179 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve The function of the brake booster check valve is to allow manifold vacuum to enter the brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the brake booster check valve: ^ Start and run the engine for at least 10 seconds. ^ Operate the brake pedal to check for power assist. ^ Disconnect the vacuum booster hose from the brake booster check valve. Do not remove the brake booster check valve from the brake booster. ^ There should be enough vacuum retained in the brake booster for at least one more power-assisted brake operation. Engine Controls, A/T - Various Driveability Issues/DTC's Cowl: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 298 Inspection Page 2587 Impact Sensor: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Locations View 151-6 Page 7865 Page 7361 With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Gasoline Fuel System Fuel Pressure Regulator: Description and Operation Gasoline Fuel System FUEL SYSTEM WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. The fuel system consists of: - an electronic returnless fuel system. - the standard fuel tank. - a fuel tank filler pipe assembly which cannot be modified in any way and is serviced only by replacement with a new filler pipe assembly. - a high temperature composite shield on the right side of the fuel tank to protect the fuel tank from the exhaust system. - a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped into the fuel tank. - a 1/4 turn fuel tank filler cap. - a fuel filter providing filtration to protect the fuel injectors. - fuel lines. - fuel pressure sensor. - a top mount, bottom sense fuel delivery module containing: the electric fuel pump which provides pressurized fuel to the engine on demand. - the fuel level sensor. - an inlet filter. - a check valve which maintains system pressure after the pump is shut off. - a pressure relief valve for overpressure protection in the event of restricted air flow. The fuel pump is controlled by powertrain control module (PCM). Electrical power to the pump is provided through the inertia fuel shutoff switch (IFS switch) located in the jack access panel on the RH side interior rear quarter trim panel. Acceleration Control The throttle is controlled by the accelerator cable which is connected to the accelerator pedal and shaft. The accelerator pedal and shaft should travel smoothly from the idle to the wide-open throttle (WOT) positions. Hesitation on return or prevention of return to the idle position must not occur. - Surrounding components such as wiring, hoses, sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft. - The sliding inner member of the accelerator cable should not be lubricated and is not serviceable. Some vehicles are equipped with adjustable brake and accelerator pedals. These pedals are serviced as an assembly. Page 6982 5. Install the shaft seal snap ring. 6. Carry out the A/C Compressor External Leak Test. 7. Install the shaft seal felt. 8. Install the A/C clutch disc and hub spacer, and the A/C clutch disc and hub. 9. Install the bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Tighten the bolt. Page 6885 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Air Inlet Door MODE DOOR ACTUATOR - AIR INLET DOOR REMOVAL NOTE: The air inlet mode door actuator can be accessed from below the RH side of the instrument panel. 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Defrost/Panel/Floor Door MODE DOOR ACTUATOR - DEFROST/PANEL/FLOOR DOOR REMOVAL NOTE: The defrost/panel/floor mode door actuator can be accessed from below the LH side of the instrument panel. Page 4215 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. System Diagnosis P0235 - P0239: Testing and Inspection For diagnosis of code P0237 refer to chart Part 1 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4632 Page 8601 Power Seat Control Module: Diagrams Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 4146 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 1328 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P1744 refer to chart Page 4683 13. Install the special tool between the fuel supply line and the fuel supply manifold. Page 4224 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Page 1660 Compressor Clutch Relay: Testing and Inspection Page 9351 Marker Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Locations View 151-11 Page 2080 Page 576 P0530 - P0534: Testing and Inspection P0533 For diagnosis of code P0533 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Page 605 Inspection Page 4168 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Accessory Delay Relay 1 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 1 Page 5699 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 Page 471 Inspection Page 8376 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 1705 Page 8828 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 4461 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 970 Inspection Engine Controls, A/T - Various Driveability Issues/DTC's Cowl: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 5011 Ignition Cable: Service and Repair Customers have reported success using the following spark plug wire placement on the coil pack." IGNITION COIL, SPARK PLUG WIRES AND SPARK PLUG Remover, Spark Plug Wire SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 6125 Page 1299 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1018 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8232 Front Door Window Glass: Service and Repair DOOR WINDOW GLASS - FRONT Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. Page 366 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3043 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Specifications Compression Check: Specifications Part 1 0f 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 4257 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a message on the vehicle communication network (SCP or HS-CAN). The key features of the PCM-VSO system are to: - Infer vehicle movement from the output shaft sensor signal - Convert transmission output shaft rotational information to vehicle speed information - Compensate for tire size and axle ratio with a programmed calibration variable - Utilize a transfer case sensor for four wheel drive applications - Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer data message via the vehicle communication network data link. The VSO hard -wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22 Hz per MPH (1.3808 Hz per 1 km/h). Page 8329 Page 7559 Special Tool(s) Page 2083 Page 7973 Page 8097 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 684 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0720 refer to chart Part 2 Page 4324 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt, Tensioner and Pulley 1. With the vehicle in neutral, position it on a hoist. 2. Remove the parts in the order indicated in the illustration and table. Part 1 0f 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Accessory Drive Belt Removal Note Page 2635 3. CAUTION: - Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS service kit components (hose, pressure sensor, electronic control unit wire harness, and connectors) through the seat cushion pan opening. 4. CAUTION: Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad with OCS bladder to the seat cushion pan and set in place. 5. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Attach the seat cushion trim cover J-clips to the seat cushion pan. If equipped with heated seats, connect the cushion element electrical connector. Engine Cooling Fan Relay 1 Page 3319 Part 2 Of 3 Page 1630 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 4 Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 2482 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 2208 Page 5592 5. Remove the SWA sensor. (Figure 1) 6. Remove the upper steering column-to-intermediate shaft bolt. 7. Remove steering column lower bearing spring (Figure 1) 8. Remove and replace the steering wheel tone ring (Figure 1) 9. To install, reverse the removal procedure and tighten steering column/intermediate shaft bolt to 22 lb-ft (30 N.m). NOTE Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Specifications Oil Pan Torque Sequence Page 7492 Part 2 4. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced (cleaning is permissible). NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused then reuse the side air bag module nuts. Remove the parts in the order indicated in the illustrations and tables. Item 1: Recliner Handle Cover Removal Note Page 7804 Part 1 Part 2 Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Page 8696 View 151-17 Page 6993 System Diagnosis P1470 - P1474: Testing and Inspection For diagnosis of code P1474 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3907 Locations View 151-10 Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Page 7112 Hose/Line HVAC: Description and Operation Auxiliary Climate Control UNDERBODY AUXILIARY A/C LINES NOTE: An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan spring lock coupling connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve. This filter must be inspected before a new thermostatic expansion valve is installed. The underbody auxiliary A/C lines carry refrigerant to the auxiliary A/C evaporator inlet, and away from the auxiliary A/C evaporator outlet. The auxiliary underbody lines have the following characteristics: The front auxiliary A/C evaporator inlet line carries high pressure refrigerant liquid from the condenser to evaporator line to the tube-in-tube type auxiliary evaporator line. - The front auxiliary A/C evaporator outlet line carries refrigerant vapor from the tube-in-tube type auxiliary evaporator line to the front evaporator outlet line. - The tube-in-tube type auxiliary evaporator line combines a high-pressure tube and a low-pressure tube into a single assembly. The high-pressure tube is located inside of, and is separate from the low-pressure tube. - Four short jumper lines connect the tube-in-tube auxiliary evaporator line to the auxiliary evaporator inlet and outlet. The jumper lines are connected at the floorpan bracket. Page 5709 Brake Pedal Assy: 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. 127-1 Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Page 7926 One Or More REAR Parking Aid Sensor(S) DOES NOT INCLUDE Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Aviator, 0.9 Hr. 2002-2005 Explorer/Mountaineer: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2004-2005 Monterey, 0.8 Hr. 2004-2005 Freestar, 2002-2003 Windstar: Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604B 2003-2005 Expedition: 1.3 Hrs. Replace One Or More REAR Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604C 2004-2005 Monterey, 1.2 Hrs. 2004-2005 Freestar, 2005 Montego, 2005 Ford Five Hundred: Replace One Or More FRONT Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604D 2003-2005 Escape, 2005 0.5 Hr. Mariner: Replace One Or Both INNER Parking Aid Sensor(S) DOES NOT INCLUDE Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604E 2003-2005 Escape, 2005 0.9 Hr. Mariner: Replace One Or Both OUTER Parking Aid Sensor(S) INCLUDES Time For Bumper Cover Removal (Do Not Use With 12651D, 12651D8, P101) 050604F Additional Time To Paint 1.0 Hr. Sensors To Match Bumper Cover On The Following Vehicles: Aviator, Page 7925 b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation procedures. ACCESSING PIDS WITH NGS, SELECT: ^ Vehicle Line ^ Diagnostic Data Link ^ PAM ^ PID/Data Monitor And Record ^ Select The Appropriate PIDS ^ Start ACCESSING PIDS WITH WDS, SELECT: ^ Tool box Icon ^ Datalogger, Then Tick (Check Mark) ^ Modules, Then Tick ^ PAM, Then Tick ^ Select The Appropriate PIDS, Then Tick NOTE FOR SOME VEHICLES, REPLACEMENT SENSORS WILL BE RECEIVED WITH A PRIMED-BLACK PAINTABLE SURFACE AND MUST BE PAINTED TO MATCH VEHICLE COLOR. REFER TO PAINTING INSTRUCTIONS BELOW. PAINTING INSTRUCTIONS ^ Use a Ford-Approved paint gun, apply base/clear coat to match vehicle ^ Surface can be cleaned with Isopropyl alcohol ^ Maximum paint curing temperature is 194~ F (90~ C) for 1 hour ^ Maximum coating thickness 125 micro meters (including the primer) ^ Paint or veil of paint must not get into connector ^ Immersion processes ARE NOT permitted ^ Paint must be applied evenly to the surface ^ Functional test must be done after painting ^ Use NGS tester to confirm settling time of the sensor is within the specified limits: 850 micro sec. to 1500 micro sec. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050604A 2004-2005 F150, 0.7 Hr. 2002-2005 Excursion, 2002 Expedition/Navigator, 2002-2005 F Super Duty, 2002-2003 Blackwood, 2005 Freestyle: Replace Page 9546 Trailer Lamps: 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. 95-1 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 1198 Inspection Page 5523 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 202 Inspection Page 7849 Page 4830 Item 7: Fuel Filler Pipe Removal Note 1. CAUTION: Some fuel will remain in the fuel filler pipe after draining the fuel tank. Carefully drain the filler pipe into an appropriate container. Separate the fuel vapor fresh air hose from the fuel filler pipe mounting bracket. Items 9, 10 and 18: Fuel Supply and Vapor Tube Quick Connect Fittings Removal Note 1. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. NOTE: If the fuel tube or retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retainer clip legs. Once the retainer clip legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Disconnect the fuel tube quick release coupling. Push the connector towards the tube to release pressure. - Press the fuel tube quick release coupling button and pull the fuel tube to disconnect. Item 12: Fuel Tank Strap Removal Note 1. After removing the center fuel tank strap and retaining bolt, position a suitable lifting device in contact, under the fuel tank. Item 19: Fuel Pump Lock Ring Removal Note Page 7754 Page 7253 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 6291 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 717 Inspection Page 5700 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 9359 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 5529 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 6172 Page 9104 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 8215 Front Door Hinge: Adjustments HINGE ADJUSTMENT - SLIDING DOOR CAUTION: For correct sliding door operation, it is critical that the door adjuster wedge and striker on the body pillar fit smoothly into the wedge pocket and latch in the power sliding door. If any of the adjustments are made, realignment of the striker may be necessary. NOTE: - Never use a wedge to adjust or fit the sliding door. Using a wedge to force the door to move will cause the wedges to squeak and eventually break. It will also cause a power sliding door to reverse prior to full closure or not close completely. - Never use the strikers to adjust the door. It will cause a rattle or affect door opening or closing efforts. Sliding Door Flushness Specifications 1. NOTE: Flushness is the inset or outset alignment of the panels to each other. Measure the door flushness. Inspect the sliding door. - Measure the door flushness according to the specifications. Page 9537 Trailer Lamps: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 5428 Item 3: Crankshaft Rear Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation. Assemble the special tools and the crankshaft rear seal. 3. Install the special tools on the rear of the crankshaft. 4. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the engine block. Page 2306 Page 4778 Fuel Pressure Sensor/Switch: Description and Operation Natural Gas Fuel System INJECTION PRESSURE SENSOR Injection pressure sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 3024 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Page 6671 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 1629 Page 7353 7. Metal finish as required. 8. Verify the nut is securely in place. 9. Install the component with the previously obtained screw. 10. Tighten the attaching screws to specification. Stripped Weld Nut WELD NUT REPAIR - STRIPPED WELD NUT 1. Remove the component from where the weld nut is to be repaired. 2. Inspect the weld nut and surrounding area for repair. - If there is not enough clearance for a larger bolt stud to go through or a larger bolt head to turn, then a threaded insert will have to be installed. Follow the instructions with the thread insert repair kit. 3. If a 6 mm weld nut is stripped, drill out the hole using a letter "H" or 0.26 in (6.5 mm) drill bit. Then tap, using an 8 mm by 1.25 bit. - Do not oversize a 6 mm weld nut by more than 8 mm. 4. If an 8 mm weld nut is stripped, drill the hole using a letter "R" or 0.3990 in (9.75 mm) drill bit. Then tap, using a 10 mm by 1.50 bit. - Do not oversize an 8 mm weld nut by more than 10 mm. 5. Obtain the appropriate oversized screw. 6. Install the attaching screw(s) to the component. 7. Tighten the attaching screws to specification. Page 6951 In-Vehicle Temperature Sensor - EATC Page 38 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7540 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 7602 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. Page 908 P1115 - P1119: Testing and Inspection P1116 For diagnosis of code P1116 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7497 to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 5. Check the active restraint system for correct operation. Item 1: Seat Side Air Bag Module Installation Note 1. WARNING: - Inspect the mounting surfaces of the side air bag module and the seat back frame mounting bracket for any foreign objects, before installing the side air bag module. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Inspect the side air bag deployment chute and the side air bag cavity in the seat back pad for any foreign objects. If any foreign objects are found remove them. Failure to do so may result in personal injury in the event of an air bag deployment. - Before installing the side air bag module, check it for damage and foreign objects. If the air bag module is damaged, replace it. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Do not disconnect the wire connector at the seat side air bag module. This is a permanent connection. Doing so may result in accidental air bag deployment, which may result in personal injury. Position the side air bag module onto the front seat backrest frame mounting bracket. Item 3: Side Air Bag Module Harness Installation Note 1. Route the side air bag module wire harness to the seat backrest frame. Item 4: Backrest Trim Cover Installation Note Page 3333 Engine Oil: Fluid Type Specifications Engine Oil .......................................................................................................................SAE 5W-20 Premium Synthetic Oil XO-5W20-QSP or equivalent Ford specification ............................................. ........................................................................................................................................... WSS-M2C153-H Page 4110 Page 664 Part 7 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8984 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Auxiliary Relay Box Page 7796 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor (OCS) system is found only on the front passenger seat. The front passenger seat OCS system is comprised of a silicone gel-filled bladder mounted in the seat cushion, a pressure sensor that is mounted to the seat frame and an electronic control unit which is also mounted to the seat frame. Pressure is applied to the OCS system bladder when weight of any occupant or object in the front passenger seat is present. The pressure is then transferred through a tube, is sensed by the OCS system pressure sensor, then electronically communicated to the OCS system electronic control unit (ECU). Based on preprogrammed set points the OCS system ECU will inform the restraints control module (RCM), via a high-speed controller area network (HS-CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module and passenger safety belt pretensioner are to be deployed in the event of a deployable collision. The RCM may also use this information to illuminate/not illuminate the passenger air bag deactivation (PAD) indicator. When an OCS system fault is present, the air bag indicator lamp will illuminate or the air bag warning chime will be activated (if an air bag indicator fault is present). The SRS then defaults the passenger air bag module to ON (activated) regardless of the size of the occupant in the front outboard passenger seat. The OCS system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. OCS system components are not to be installed separately. If installing a new OCS system, OCS system component or seat cushion foam pad, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. The OCS system also interprets a variable voltage signal provided by the safety belt tension sensor to identify the presence of a child safety seat in the front outboard passenger seat. The OCS system then communicates with the restraints control module (RCM), automatically deactivating the passenger air bag module and passenger safety belt pretensioner. Refer to Safety Belt Tension Sensor. Page 2826 Spark Plug: Specifications Torque Spark Plug Torque ............................................................................................................................... ...................................................... 11 ft. lb. (15 Nm) Service and Repair Front Door Panel: Service and Repair FRONT DOOR TRIM PANEL REMOVAL NOTE: LH side is shown. RH side is similar. 1. Remove the parts in the order indicated in the illustration and table. Item 1: Mirror Access Panel Removal Note Page 4998 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 1390 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7510 Service and Repair Front Door Exterior Handle: Service and Repair FRONT DOOR HANDLE Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Passenger side shown, driver side similar. 1. Remove the front door trim panel. Page 3659 Thermostat: Service and Repair Thermostat and Thermostat Housing Material Material 1. Partially drain the cooling system. 2. Remove the air cleaner outlet tube. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 6071 Page 5174 Case: Specifications Case-to-chain cover (10 mm socket size) ................................................................................................................................................. 26 Nm (19 ft. lbs.) Case-to-chain cover (8 mm socket size) ..................................................................................................................................................... 12 Nm (9 ft. lbs.) Chain cover-to-case (10 mm socket size) ................................................................................................................................................. 25 Nm (18 ft. lbs.) Chain cover-to-case (24 mm socket size) ................................................................................................................................................. 31 Nm (23 ft. lbs.) Chain cover-to-case (13 mm socket size) ................................................................................................................................................. 43 Nm (32 ft. lbs.) Chain cover-to-case bolts (8 mm socket size) ............................................................................................................................................. 11 Nm (8 ft. lbs.) Case-to-stator support ............................................................................................................. .................................................................... 11 Nm (8 ft. lbs.) Page 2012 View 151-15 Page 1144 Inspection Evaporative Emissions System DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITORING SYSTEM (TPMS) Your vehicle may have a temporary spare tire. The temporary spare tire for your vehicle is labeled as such. It is smaller than a regular tire and is designed for emergency use only. Replace this tire with a full-size tire as soon as possible. Note: The Low Tire Pressure Warning system (if equipped) will detect the temporary spare tire and illuminate the low tire warning light until the spare tire is replaced with a proper full-size tire. Page 5909 1. Disconnect the speed control and the accelerator cables. 2. Remove the wiring harness retaining bracket. 3. Remove the cable bracket bolts and position bracket aside. 4. Remove the bolts and position the speed control module aside. Item 17: Brake Reservoir Cap Removal Note 1. If removing the brake fluid reservoir, use a suitable suction device to drain the reservoir before removal. Page 5524 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Locations View 151-13 Locations View 151-9 P2275 P2275 - P2279: Testing and Inspection P2275 For diagnosis of code P2275 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 4833 Hook the fuel gauge sending unit on the fuel pump module. 3. NOTE: The grounding eyelet must be on the front side of the sending unit. Install the screw through the grounding eyelet and tighten the screw. 4. Slide the heat shrink tube onto the wire harness and connect the electrical connector. 5. WARNING: Do not use an open flame to heat the heat shrink tube, only use a heat gun. Using a heat gun, heat the heat shrink tube. 6. Wrap the sending unit wire around the fuel pump module wire harness to make sure the wire will not interfere with the movement of the fuel gauge sending unit float arm. Page 3530 Part 4 Of 4 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 11: Coolant Pump Pulley Bolts Removal Note 1. Remove the engine mount nuts. Page 9573 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 1370 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1783 refer to chart Page 3112 Relay Box: Diagrams Smart Junction Box (SJB) Locations View 151-6 Restraints - Control Module DTCs & Associated Fault PIDs Air Bag Control Module: All Technical Service Bulletins Restraints - Control Module DTCs & Associated Fault PIDs TSB 07-12-3 06/25/07 RCM FAULT REPORTING USING DTCS AND BIT-MAPPED PARAMETER IDENTIFIERS (PIDS) - SERVICE TIPS FORD: 2001-2007 Crown Victoria 2002-2007 Taurus 2004-2007 Focus 2005-2007 Five Hundred, Freestyle, Mustang 2006-2007 Fusion 2001-2003 Explorer Sport 2001-2007 Explorer Sport Trac 2002-2003 Windstar 2002-2007 Explorer 2003-2007 Expedition 2004-2007 F-150, Freestar 2005-2007 Escape Hybrid, Escape 2007 E-Series LINCOLN: 2001-2007 Town Car 2003-2006 Lincoln LS 2006 Zephyr 2007 MKZ 2003-2005 Aviator 2003-2007 Navigator 2006-2007 Mark LT MERCURY: 2001-2007 Grand Marquis 2002-2005 Sable 2005-2007 Montego 2006-2007 Milan 2002-2007 Mountaineer 2004-2007 Monterey 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 07-7-8 to update the vehicle application. ISSUE Various 2001-2007 vehicles are equipped with a restraints control module (RCM) that report diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific fault. Most 2001-2006 Workshop Manuals (WSM) were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS) or Worldwide Diagnostic System (WDS). ACTION Refer to the Service Tips to assist with navigation of both the WSM and the scan tool being used. SERVICE TIPS DTCs And Associated Fault PIDs Description Many of the continuous memory and on-demand DTCs that can be present in the RCM provide general fault information and require accessing the associated bit-mapped PIDs (fault PIDs) to identify the specific concern. DTCs that use fault PIDs are conceptually different from conventional DTCs. Conventional DTCs identify a specific concern for a given component and point to a particular diagnostic path. In the diagnostic path, PIDs are sometimes used to determine the root cause. Page 3919 Power Steering Pressure Switch: Service and Repair POWER STEERING POSITION (PSP) SWITCH REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Ignition Lock: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Page 64 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6014 Item 1: Ignition Key Removal Note 1. Turn the ignition key to the RUN position. Item 2: Lock Cylinder Button Removal Note 1. Using a suitable tool, press the ignition lock cylinder release button. Item 3: Ignition Lock Cylinder Removal Note 1. Remove the ignition lock cylinder by pulling outward. INSTALLATION 1. To install, reverse the removal procedure. Page 5282 Transmission Cooler: Component Tests and General Diagnostics Transmission Fluid Cooler Leaks at Radiator Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler fitting (not the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the fluid cooler fitting. Insufficient thread sealer on the transmission fluid cooler fitting may cause this. 1. Clean the area around the transmission fluid cooler fittings. 2. Verify that transmission fluid is leaking between the transmission fluid cooler and the transmission fluid cooler fitting (not the transmission fluid cooler line fitting into the transmission fluid cooler fitting). 4. CAUTION: Oil-based solvents and cleaners should not be used when cleaning the radiator. Oil-based solvents and cleaners can damage the radiator end tank seals and cause leaks. Clean the area around the transmission fluid cooler fittings so that contaminants do not enter the transmission fluid cooler when the transmission fluid cooler fittings are removed. 5. NOTE: Remove only one transmission fluid cooler fitting at a time, otherwise the cooler may drop into the radiator. Remove the upper transmission fluid cooler fitting. 6. Once the fitting is removed from the transmission fluid cooler, verify that there is a gasket between the transmission fluid cooler and the inside of the radiator tank. ^ If there is no gasket, install a new radiator. ^ If there is a gasket, proceed to the next step. Locations View 151-5 Page 9726 Wiper Switch: Diagrams Page 8028 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 2 Page 5365 2. NOTE: If necessary, use a nonmetallic mallet to aid in seating the circlip in the differential side gear groove (RH) or output shaft splines (LH). Tap only on the outboard front wheel halfshaft joint. Align the inboard CV Joint housing splines with the differential side gear splines (RH) or output shaft splines (LH), and push the inboard CV joint housing assembly inward until the circlip seats in the differential side gear (RH) or inboard CV joint housing (LH). 3. Align the halfshaft outboard CV joint splines and the wheel hub splines, and push the joint into the wheel hub as far as possible. 4. Install the washer and the original wheel hub retainer. Using the old retainer, seat the outboard CV joint in the hub. Remove the retainer and discard it. Item 3: Lower Control Arm Ball Joint Pinch Bolt Installation Note 1. CAUTION: Install a new bolt and nut. Connect the suspension lower arm to the knuckle and install the new bolt and nut. Page 7335 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 8729 Condenser to Evaporator Line Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE REMOVAL CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting that has been disconnected. 1. Position the vehicle on a hoist with the gear selector in NEUTRAL. 2. Recover the refrigerant. 3. Remove the wiper motor and pivot assembly. Page 6576 Alignment: Service and Repair Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the straight-forward position by attaching a rigid link from the steering wheel to the seat. 3. Check the toe settings. Follow the manufacturer's instructions. 4. Remove the clamps. 5. Loosen the nuts. ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. 6. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Page 2437 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 911 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection C110-C315 Multiple Junction Connector: Diagrams C110-C315 Page 4656 View 151-5 (Engine, Rear) CAUTION: A new PCV valve must be installed if removed from the valve cover. Damage will occur to the locking mechanism on the removed PCV valve. Rotate the PCV valve counterclockwise and remove the PCV valve from the valve cover. To install, reverse the removal procedure. Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Page 1931 Page 9373 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Locations Page 2877 Special Tool(s) Page 920 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 759 P0755 - P0759: Testing and Inspection P0758 Torqshift For diagnosis of code P0758 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Auxiliary Blower Motor Relay Page 7663 Page 278 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8216 2. NOTE: If the upper and lower wedges are not loosened, it will pull the sliding door into the same position the door was in before the adjustment. The wedges should be loosened enough to move, but not so loose that they cannot hold their position when moved. Loosen the screws. 3. NOTE: The B-pillar wire striker should be centered in the catch assembly opening. Do not use the B-pillar wire striker to position the door. Inspect the alignment of the B-pillar wire striker in the catch. If the striker is not centered, proceed as follows: Mark the edges of the striker. - Slightly loosen the screws. - Tap the striker into the correct position. - Tighten the screws. 4. NOTE: The C-pillar striker should be centered in the latch assembly opening. Do not use the C-pillar striker to position the door in an up or down Output Shaft Speed Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed Sensor OUTPUT SHAFT SPEED SENSOR The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (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 generated. Page 5197 Page 656 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8074 Symbols Part 2 Page 4839 Mechanical Returnless Fuel Pump Module (FPM) Page 3831 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 2905 Attachment I - Administrative Information OASIS ACTIVATED? ^ Ford Freestar - Yes ^ Mercury Monterey - OASIS will be activated 11/04/03 FSA VIN LIST ACTIVATED? ^ Ford Freestar - Yes ^ Mercury Monterey - FSA VIN list will be activated 11/04/03. NOTE: 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 action. STOCK VEHICLES Correct all affected stock vehicles before delivery. SOLD VEHICLES ^ Owners of affected vehicles will be directed to dealers for repairs. ^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date. ^ Also correct other affected vehicles identified in OASIS which are brought to your dealership. RELATED DAMAGE Related damage claims are not approved for this program. ADDITIONAL LABOR TIME ^ This repair will require no additional labor time to complete. Claims submitted with "MT" labor will not be accepted for reimbursement. ^ 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 ^ Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the repair was performed prior to the date indicated in the reimbursement plan which is posted with this bulletin. This plan is also available to owners through the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement through authorized dealers or at their option directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121. Page 6950 Cabin Temperature Sensor / Switch: Description and Operation ELECTRONIC AUTOMATIC TEMPERATURE CONTROL In-Vehicle Temperature Sensor The in-vehicle temperature sensor operates in the following manner: - A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger compartment. - An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. - The aspirator hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor. - The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor. Page 6079 connections. Retest. 4. If the voltage is more than 0.5 volt, install a new cable. If the voltage reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor. Page 5907 Part 1 Of 2 Locations View 151-5 Description and Operation Seat Belt Reminder Buzzer: Description and Operation SAFETY BELT WARNING SYSTEM - DRIVER SAFETY BELT The driver safety belt incorporates a safety belt warning indicator switch, warning indicator and chime. The warning indicator and chime are reminders to fasten the safety belt. If the driver safety belt is not buckled before the ignition key is turned to the ON position, the safety belt warning light illuminates for one to two minutes and the warning chime sounds for four to eight seconds. - If the safety belt is buckled while the warning indicator is on and the chime is sounding, the warning light and warning chime turn off. - If the safety belt is buckled before the key is turned to the ON position, the warning indicator will come on for four to eight seconds with no chime. BELT MINDER The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides additional reminders to the driver that the driver safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster. The passenger safety belt minder feature is activated only when the occupant classification sensor (OCS) system detects a passenger in the right front seat and the passenger weight exceeds a programmed set point. To activate or deactivate the belt minder feature, refer to Instrument Panel, Gauges and Warning Indicators. Page 5007 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8166 Page 629 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6356 Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER The fuel rail pulse damper located on the fuel rail reduces fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail pressure.) Page 3980 Fuel Temperature Sensor: Description and Operation ENGINE FUEL TEMPERATURE SENSOR Engine fuel temperature sensor which measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulsewidth and meter fuel to each engine combustion cylinder. Page 1154 Inspection Page 6390 Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 1985 View 151-14 Page 7204 Page 8378 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 4696 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 8712 Door Position Switch: Locations View 151-14 Page 976 P1180 - P1184: Testing and Inspection P1181 For diagnosis of code P1181 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2272 Page 7262 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Page 8862 2 Rotate the speed control cable cap counterclockwise. INSTALLATION 1. To install, reverse the removal procedure. Item 3: Speed Control Cable Installation Note 1. NOTE: Incorrect wrapping of the speed control cable core wire around the speed control actuator pulley may result in a high idle condition. Insert the speed control cable slug into the speed control actuator pulley slot. 1 Gently push the retaining spring. 2 Insert the speed control cable slug completely into the speed control actuator pulley slot. 2. NOTE: Make sure the rubber seal is correctly seated onto the speed control cable cap. Align the speed control cable cap tabs with the slots in the speed control actuator housing and seat the speed control cable cap. 3. Rotate the speed control cable cap clockwise until the locking tab engages. Item 2: Speed Control Cable Installation Note 1. Make sure the tabs on the speed control cable are locked in place and that the cable is fully seated in the bracket. Page 2288 Specifications Piston: Specifications Piston diameter-coded red (before coating) .................................................................................................... 96.795-96.782 mm (3.81082-3.81031 inch) Piston diameter-coded blue (before coating) ................................................................................................... 96.808-96.795 mm (3.81133-3.81082 inch) Piston diameter-coded yellow (before coating) ................................................................................................ 96.821-96.808 mm (3.81184-3.81133 inch) Piston-to-cylinder bore clearance (uncoated clearance) ........................................................................................ 0.018-0.044 mm (0.00071-0.00173 inch) Page 3902 View 151-4 P0205 P0205 - P0209: Testing and Inspection P0205 OBD II - Base Gasoline For diagnosis of code P0205 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8647 - Make sure a minimum five second time period has passed after cycling the ignition switch ON before the rezeroing process. - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. NOTE: The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, the new trim cover or a seat side shield is removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 4. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 5. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). 6. Disconnect the battery ground cable and wait at least one minute. 7. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Reactivate the supplemental restraint system (SRS). 8. Connect the battery ground cable. 9. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 674 - For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0717 refer to chart Page 9207 DTC Index B1342 - B2534 Page 3064 Fuse: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Electrical Specifications Battery: Electrical Specifications Amps/Hour Rate/Volts/Cold Cranking Amps ITEM..................................................................................................................................................... ...................................................SPECIFICATION Battery Voltage................................................................................................................................................. ........................................................................12 volts Cold cranking amps........................................ ..........................................................................................................650 CCA (standard) 750 CCA (optional) Battery amps rating................................................................................................................................................72 amp/hr (standard) 78 amp/hr (optional) Parasitic Draw Parasitic Draw (Current Drain)........................................................................................................................................Less than 50 milliamps (0.050 amp) NOTE: For testing procedures, please refer to Battery Drain Test. Page 9171 Ambient Light Sensor: Service and Repair LIGHT SENSOR REMOVAL 1. Remove the LH and RH windshield side garnish mouldings. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6158 Page 7934 Page 7812 Part 1 Testing and Inspection Micro ISO Relay: Testing and Inspection Page 7580 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 8. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 9. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 10. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 11. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 5. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 7. Through the glove compartment opening, connect the passenger air bag module electrical connector. 8. Close the glove compartment. 9. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 10. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 11. Close the steering wheel access door. 12. Reconnect the battery ground cable. 13. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is Page 2827 Spark Plug: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Spark Plug: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Locations View 151-22 Page 8115 DTC Index B1342 - B2070 Page 6916 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 2 Page 6841 Wheel Bearing: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. Page 8150 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 8988 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 5690 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 4108 Disclaimer Page 6683 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 9203 90-3 Page 6769 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 6236 Page 1251 P1635 - P1639: Testing and Inspection P1639 For diagnosis of code P1639 refer to Note 11: NOTE 11: The Vehicle ID (VID) Block must be reprogrammed. For instructions, refer to the Flash VID Block Procedure. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4801 Fuel Pump Control Unit: Service and Repair FUEL PUMP DRIVER MODULE (FPDM) REMOVAL 1. Remove the LH lower B-pillar trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6540 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 9292 Page 2018 View 151-15 Locations Page 4976 DEALER CODING CONDITION BASIC PART NO. CODE 9F955 33 Disclaimer System Diagnosis P1395 - P1399: Testing and Inspection For diagnosis of code P1397 refer to NOTE 36: NOTE 36: Refer to the Charging System and diagnose the charging system concern. See: Starting and Charging/Charging System/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1560 Power Sliding Door Module: Service Precautions WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. Page 5895 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 8813 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 9333 Traction Control - Short Duration Activation Steering Angle Sensor: All Technical Service Bulletins Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Page 3997 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). Page 4207 MOTORCRAFT(R) CLEAR SILICONE RUBBER, TA-32, CAN NOT BE USED SINCE ITS CONSTITUENTS MAY DAMAGE THE PCM CIRCUITRY. 9. Carefully blow off the PCM internals with filtered, dry air at 5-10 PSI (34-69 kPa) to ensure all components are dry and clean. 10. Reassemble the PCM, and bend the retaining clips back fully. Make sure a full seal is created around the top edge of the PCM - add sealant as required. (Figure 8) Page 1291 P1710 - P1714: Testing and Inspection P1711 Torqshift For diagnosis of code P1711 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6252 Page 1725 Service and Repair Engine Mount: Service and Repair Engine Mount Special Tools And Equipment Special Tool(s) 1. If removing the RH, LH or rear engine mount, the vehicle must be lifted on a hoist during this procedure. With the vehicle in neutral, position it on a hoist. 2. If removing the RH, LH or rear engine mount, remove the hood. 3. If removing the RH, LH or rear engine mount, remove the wiper motor and pivot assembly. 4. Remove the parts in the order indicated in the illustrations and tables. part 1 Of 3 Page 886 P1000 - P1004: Testing and Inspection P1001 For diagnosis of code P1001 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8727 Door Position Switch: Diagrams Page 3601 4. Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, install a new heater core. Page 6234 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 3063 Page 1509 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 305 Inspection Page 6450 Page 3645 Page 3081 Page 4886 Page 1111 Inspection Page 5708 Page 1326 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Left System Diagnosis P2135 - P2139: Testing and Inspection For diagnosis of code P2135 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4205 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Locations View 151-5 Locations View 151-18 Page 6143 Fuse Block: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. 4R70W P0745 - P0749: Testing and Inspection 4R70W For diagnosis of code P0748 refer to chart Part 9 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7820 3. CAUTION: - Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS service kit components (hose, pressure sensor, electronic control unit wire harness, and connectors) through the seat cushion pan opening. 4. CAUTION: Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad with OCS bladder to the seat cushion pan and set in place. 5. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Attach the seat cushion trim cover J-clips to the seat cushion pan. If equipped with heated seats, connect the cushion element electrical connector. Specifications Compression Check: Specifications Part 1 0f 2 Part 2 Of 2 The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 7388 CAUTION: Make sure the road wheels are in the straight-ahead position. If the vehicle s clockspring has rotated out of center, follow these steps to center the clockspring. 1 Hold the clockspring outer housing stationary. 2 CAUTION: Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and for a slight resistance. Stop turning at this point. 3 Turn the clockspring clockwise approximately three turns. This is the center point of the clockspring. Do not allow the rotor to turn from this position. Page 6405 Electrical - Wiring Soldering/Crimping Service Tips Technical Service Bulletin # 05-18-7 Date: 050922 Electrical - Wiring Soldering/Crimping Service Tips TSB 05-18-7 09/22/05 WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006 Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005 Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006 F-650, F-750 2006 Low Cab Forward LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego 2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model years. ISSUE Wire harness repairs are supported through the availability of individual components such as: ^ Wire terminals with machine crimped pigtails ^ Hard shell connectors ^ Dual wall heat shrink tubing ^ Complete, loaded, wiring pigtail kits Some of the available tools and service parts that are helpful when performing wiring harness repairs are: ^ Motorcraft Wiring Pigtail Catalog (see website for more information) ^ Rotunda Wire Splice Tool kit 164-R5903 ^ General Wire Terminal Repair Kit (order through Ford Component Sales) Page 1378 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: Page 6869 View 151-27 Page 2267 P0705 P0705 - P0709: Testing and Inspection P0705 4R70W For diagnosis of code P0705 refer to chart Part 2 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1610 Electronic Brake Control Module: Diagrams Specifications Transmission Speed Sensor: Specifications Turbine shaft speed (TSS) sensor retaining bolt ......................................................................................................................................... 11 Nm (8 ft. lbs.) Output shaft speed (OSS) sensor retaining bolt .......................................................................................................................................... 11 Nm (8 ft. lbs.) Page 9078 Page 4710 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 4376 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 7264 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Engine Controls, A/T - Various Driveability Issues/DTC's Engine Control Module: All Technical Service Bulletins Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 6471 Note: The bussed electrical center is located in the engine compartment. Page 7007 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Page 8458 Part 1 Page 8254 Part 1 Page 6137 Page 6527 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Page 661 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Liftgate Ajar Switch Page 9682 2. Disconnect the two rear window defrost electrical connectors. 3. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. WARNING: To prevent glass splinters from entering the eyes or cutting the hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. CAUTION: Care must be taken to avoid scratching the pinch weld. 4. NOTE: Lubricate the existing urethane adhesive with water to aid the special tool while cutting. Using the special tool, cut the adhesive away from the liftgate window glass and remove the liftgate window glass. 5. Using a soft brush or vacuum, remove the dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Liftgate Window Glass Installation Note CAUTION: After installing the new urethane-installed liftgate window glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. 1. Dry-fit the liftgate window glass by centering it side-to-side and by adjusting the setting blocks (if equipped ) to get the correct position top and bottom. Use tape or non-permanent marking pencil to make alignment marks on the glass and the vehicle body. 2. After alignment, remove the rear window glass and molding assemblies from the vehicle and place them on a stable work surface. CAUTION: Care must be taken to avoid scratching the pinch weld. 3. Trim the remaining urethane adhesive on the pinch weld using only the full-cut method. In this method, most of the existing urethane adhesive is removed leaving a level bead around the entire pinch weld. 4. WARNING: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM recommended curing automotive paint primer and allow to cure correctly. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean Page 1302 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Testing and Inspection Tire Pressure Sensor: Testing and Inspection Vehicles Without Message Center To reset the system, press and hold the odometer reset button and wait for the "TIRE PRESSURE SET" light to illuminate. Continue to press the button for 3 seconds, then release. After 3 seconds, the low tire pressure warning lamp will flash 3 times, indicating that the low tire warning system reset procedure is complete. Vehicles With Message Center To reset the system, press and hold the SETUP button and wait for the message center to display "REST FOR SYSTEM CHECK". Then press the RESET button and wait for the message center to display "HOLD RESET TO RELEARN". Press and hold the RESET button for 3 seconds. The message "HOLD RESET TO RELEARN" and the low tire warning lamp will flash 3 times, indicating the reset procedure is complete. Page 3423 7. Drain the engine oil and refill with clean engine oil. Item 8: Crankshaft Pulley Removal Note 1. Disconnect the RH front anti-lock brake wheel sensor electrical connector. 2. Position a safety stand under the RH side of the subframe. 3. Lower the RH side of the subframe 50.8 mm (2 inch). - Remove the bolts. - Lower the subframe. Page 2906 ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall must still be performed even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the FSA's repair line. Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION There are no parts required for this recall. Attachment III - Technical Information OVERVIEW Page 1836 Master Window/Door Lock/Unlock Switch Power Door Lock Switch: Diagrams Master Window/Door Lock/Unlock Switch Page 1197 P1510 - P1514: Testing and Inspection P1513 For diagnosis of code P1513 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3910 Oxygen Sensor: Service and Repair HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR Socket, Exhaust Gas Oxygen Sensor SPECIAL TOOL(S) REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. Item 2: HO2S and Catalyst Monitor Sensors Removal Note Page 8688 119-2 Page 3070 Fuse Block: Locations Bussed Electrical Center (BEC) Page 736 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3512 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 3016 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. A/T - Erratic Fluid Level Readings/Filler Tube Leaks Case: All Technical Service Bulletins A/T - Erratic Fluid Level Readings/Filler Tube Leaks TSB 06-18-13 09/18/06 ERRATIC FLUID LEVEL READING ON TRANSAXLE DIPSTICK - LEAKS - 4F50N, AX4N, AX4S FORD: 2000-2007 Taurus 2000-2007 Windstar 2004-2007 Freestar MERCURY: 2000-2005 Sable 2004-2007 Monterey This article supersedes TSB 05-14-5 to update the Service Procedure and vehicle model years. ISSUE Some 2000-2007 Taurus, 2000-2005 Sable, 2000-2003 Windstar, and 2004-2007 Freestar/Monterey vehicles, equipped with a 4F50N, AX4N, or AX4S transaxle, may exhibit an erratic fluid level reading on the transaxle dipstick and possible leaks around the filler tube and grommet. The condition may be due to a restricted transaxle vent. ACTION Repair the transaxle vent restriction by replacing the transaxle vent with a 90° vent stem, small hose clamp, two (2) tie raps, and 24" (61 cm) of 5/16" (8 mm) vacuum hose. The 5/16" (8 mm) vacuum hose will be routed from the 90° vent on the transaxle back to the cowl area, next to the brake master cylinder and tie rapped in place with the end of the hose facing down. Refer to the following Service Procedures. NOTE ON WINDSTAR, FREESTAR AND MONTEREY SEAL THE COWL PANEL GRILLE (COWL TO VENT PANEL) AREA, SEE TSB 06-14-10. NOTE LEAKS MAY BE MISDIAGNOSED AS COMING FROM THE PAN GASKET. ALWAYS FOLLOW WORKSHOP MANUAL, SECTION 307-01 TO LOCATE THE SOURCE OF A LEAK, AND LEAK CHECK WITH BLACK LIGHT AND DYE. SERVICE PROCEDURE 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Disconnect the crankcase vent tube(s) from the air cleaner outlet pipe. 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body. 4. Release the air cleaner housing clamp(s). 5. Separate the air cleaner cover from the air cleaner tray. 6. Windstar, Freestar and Monterey only: Remove cowl panel grille by following the procedure in TSB 06-14-10. 7. Disconnect the shift cable if located over the top of the vent. 8. Remove the vent, pull straight up on the vent with locking pliers, or carefully pry the vent from the transaxle case. 9. Install the replacement 90° vent stem. Page 8665 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Drivetrain - Outer CV Joint(s) Broken Constant Velocity Joint: Customer Interest Drivetrain - Outer CV Joint(s) Broken TSB 05-9-8 05/16/05 OUTER CV JOINT BROKEN - VEHICLES BUILT BEFORE 5/1/2005 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles built before 5/1/2005, may exhibit a broken outer C/V joint. This may occur when the vehicle steering is turned hard in one direction and the vehicle is accelerated at a high rate. ACTION Replace the outer C/V joint and install restrictors between the inner tie-rod ends and the steering rack. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Replace the halfshaft (right and/or left). Refer to Section 205-04 of the Workshop Manual. 2. Remove the steering gear. Refer to Section 211-00 of the Workshop Manual. If present, note the orientation of the steering gear vent tube. During reinstallation the bellows and vent tube must be installed in the correct orientation. NOTE THE BELLOWS AND CLAMPS ON THE STEERING GEAR ARE DESIGNED TO PROVIDE AN AIRTIGHT SEAL TO PROTECT THE INTERNAL COMPONENTS. IF THE BELLOWS SEAL IS NOT AIRTIGHT THE VACUUM GENERATED DURING TURNING WILL DRAW WATER AND CONTAMINATION INTO THE GEAR CAUSING PREMATURE WEAR. ZIP TIES DO NOT PRODUCE AN AIRTIGHT SEAL AND MUST NOT BE USED IN PLACE OF THE BELLOWS CLAMPS. 3. Drain any excess power steering fluid from the steering gear and clean the exterior of the gear using a suitable solvent. 4. Remove and discard the two (2) inner bellows clamps. New clamps must be installed. 5. Slide the two (2) steering gear bellows aside to allow access to the inner tie-rods. 6. Thoroughly clean any abrasive material from the inside of the bellows area. Thoroughly clean and inspect all the parts being reused. 7. Install the restrictors on each side of the rack between the inner tie-rod and the steering gear housing (Figure 1). 8. Position two (2) new inner bellows clamps onto the steering gear. DO NOT secure the inner bellows clamps at this point. 9. Install the two (2) steering gear bellows over the steering gear. Locations View 151-5 Page 9223 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION SWITCH Typical Brake Pedal Position Switch The brake pedal position (BPP) switch (Figure 27) is used by the PCM to disengage the transmission torque converter clutch and on some applications as an input to the idle speed control for idle quality and for vehicle speed control deactivation. Depending on the vehicle application the BPP switch can be connected to the PCM in the following manner: - BPP switch is hard wired to the PCM supplying battery positive voltage (B+) when the vehicle brake is applied. - BPP switch is hard wired to a module (ABS, LCM or HEM), BPP signal is than broadcasted over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake (ABS)- traction control / stability assist module. The stability module will interpret the BPP switch input along with other ABS inputs and generate an output called the Driver Brake Application (DBA) signal. The DBA signal is than sent to the PCM and to other BPP signal users. Note on applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor in the PCM. This provides fail-safe operation in the event the circuit to the stoplamp bulbs has failed. Page 2062 Power Mirror Switch: Testing and Inspection Page 7642 Seat Belt: Service and Repair General Procedures Safety Belt Maintenance SAFETY BELT MAINTENANCE WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjuster, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected. New safety belt assemblies should be installed if either damage or incorrect operation is noted. 1. The safety belt assemblies should be periodically inspected to make sure that they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. 2. Before installing the new safety belt assembly; the safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. 3. Install the new safety belt(s) using the appropriate instructions. Carry out the Functional Test Procedure. See: Testing and Inspection/Component Tests and General Diagnostics Safety Belt Cleaning SAFETY BELT CLEANING 1. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. Safety Belt With Anchor Plate Thread Damage SAFETY BELT WITH ANCHOR PLATE THREAD DAMAGE 1. NOTE: The lap/shoulder safety belts are factory-installed in their correct locations. If the belts are removed for any reason, they must be installed in their original location; refer to removal and installation. The 7/16 x 20 Torx (R) head anchor bolts must be hand-started and then tightened to 40 Nm (30 lb-ft). Remove the broken or stripped bolt. 2. Drill out the internal threads in the safety belt anchor plate with a 27/64-inch drill. 3. Rethread the anchor plate with a 1/2-13 tap. 4. Blow out the chips. 5. NOTE: New service parts are to be used in place of the original parts; refer to the Parts Replacement Chart-Safety Belt With Damaged Weld Nut Anchor Plate Threads in Specifications. Install the attachment parts in the correct sequence. Install a new bolt, hand-tighten and then tighten the bolt to 40 Nm (30 lb-ft). Replacement of the Weld Nut and Reinforcement REPLACEMENT OF THE WELD NUT AND REINFORCEMENT 1. NOTE: If the B-, C- or D-pillar safety belt anchor nuts or reinforcements are stripped or missing, a new nut/reinforcement plate must be installed. Expose the suspect anchor point. 2. Drill out two 8 mm (5/16 inch) diameter access holes adjacent to the weld nut clearance hole. 3. Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer. 4. Use MIG wire feed welder and plug weld a 7/16 inch weld nut and standard washer in place at the two 8 mm (5/16 inch) holes. 5. Metal finish as necessary. 6. Install the restraint system. 7. Carry out the Functional Test. See: Testing and Inspection/Component Tests and General Diagnostics Safety Belt Tongue Rotated on Belt SAFETY BELT TONGUE ROTATED ON BELT Page 3283 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. System Diagnosis P0360 - P0364: Testing and Inspection For diagnosis of code P0360 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Service Precautions Ignition Cable: Service Precautions CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. - Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Page 4387 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Locations View 151-5 Page 4289 P1137 P1135 - P1139: Testing and Inspection P1137 For diagnosis of code P1137 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7542 Air Bag Control Module: Locations View 151-8 Diagrams Cargo Lamp: Diagrams Page 6218 Page 4890 Page 4826 Fuel Filler Hose: Vehicle Damage Warnings CAUTION: - Some fuel will remain in the fuel filler pipe after draining the fuel tank. Carefully drain the fuel pump module/filler pipe into an appropriate container. - 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 the tube. - The fuel pump module must be handled carefully to avoid damage to the float arm and filter. - Make sure the fuel tube clicks into place when installing the tube. To make sure the tube is fully seated, pull on the tube. Page 3412 5. Install the timing chain, crankshaft gear and camshaft gear as an assembly. 6. Make sure that the timing marks and the keyways are aligned. 7. Remove the retaining pin. 8. Install the synchronizer drive gear. Items 16-10: Engine Front Cover Installation Note 1. CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage. CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage. Page 7763 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining nuts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. - Make sure the radiator support and front impact severity sensor mating surfaces are clean and debris free. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure First Row SIDE IMPACT SENSOR - FIRST ROW Page 2525 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION SENSOR Typical Hall-Effect Sensor Typical Variable Reluctance Sensor The camshaft position (CMP) sensor detects the position of the camshaft. The CMP sensor identifies when piston No.1 is on its compression stroke. A signal is then sent to the powertrain control module (PCM) and used for synchronizing the sequential firing of the fuel injectors. The Coil On Plug (COP) ignition applications also use the CMP signal to select the proper ignition coil to fire. The input circuit to the PCM is referred to as the CMP input or circuit. DTC P0340 is associated with this sensor. Vehicles with two CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 28) found on F-Series 4.2L applications, and the two pin connector variable reluctance sensor found on all other vehicles (Figure 29). P1700 P1700 - P1704: Testing and Inspection P1700 For diagnosis of code P1700 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7032 4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting. 5. Install the spring lock coupling clip. Page 1838 Page 3847 View 151-13 Page 5810 5. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. 6. Tighten the RH rear bleeder screw. 7. Repeat Steps 3, 4, 5 and 6 for the LH rear bleeder screw. 8. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 9. Have an assistant hold firm pressure on the brake pedal. 10. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. ^ Repeat until clear, bubble-free fluid comes out. ^ Refill the brake master cylinder reservoir as necessary. Page 3242 1. Install the rocker arms. - Position the rocker arms and pivots. - Hand-start the bolts. - Tighten the bolts in two stages. Stage 1: Tighten to 5 Nm (44 inch lbs.). - Stage 2: Tighten to 32 Nm (24 ft. lbs.). Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Page 4360 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 8682 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 87 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1755 Relay Box: Application and ID Bussed Electrical Center (BEC) Page 4840 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module (Figure 71),(Figure 72) and(Figure 73) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 7354 Special Tool(s) P0505 P0505 - P0509: Testing and Inspection P0505 For diagnosis of code P0505 refer to chart P0505-P0722 NOTE 9: Refer to the Description, Possible Causes and Diagnostic Aids for the DTC in question. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle Service Precautions Headliner: Service Precautions WARNING: Windshield washer solvent contains methanol which is poisonous. Observe all cautions and warnings indicated on the label of the washer solvent container. Failure to follow these instructions may result in personal injury. Service and Repair Coolant Reservoir: Service and Repair REMOVAL AND INSTALLATION Material Material 1. Drain the cooling system. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. 4. Fill and bleed the cooling system. Page 1622 Description and Operation Expansion Valve: Description and Operation THERMOSTATIC EXPANSION VALVE NOTE: An in-line filter is installed in the auxiliary evaporator inlet line at the floorpan spring lock coupling connection. A restriction in this filter may cause misdiagnosis of a failed thermostatic expansion valve. This filter must be inspected before a new thermostatic expansion valve is installed. A thermostatic expansion valve automatically regulates the flow of refrigerant into the auxiliary evaporator core. It is also the dividing point in the system between low- and high-pressure sides. The temperature sensing bulb measures the temperature of the refrigerant in the suction line and transmits it to the thermostatic expansion valve. This temperature variation regulates the refrigerant flow to the auxiliary evaporator core. - When the bulb senses a high temperature, the thermostatic expansion valve opens and floods refrigerant through the auxiliary evaporator core. - When the bulb senses a low temperature, the thermostatic expansion valve starts closing to shut off the refrigerant to the auxiliary evaporator core. Description and Operation Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITORING SYSTEM (TPMS) Your vehicle may have a temporary spare tire. The temporary spare tire for your vehicle is labeled as such. It is smaller than a regular tire and is designed for emergency use only. Replace this tire with a full-size tire as soon as possible. Note: The Low Tire Pressure Warning system (if equipped) will detect the temporary spare tire and illuminate the low tire warning light until the spare tire is replaced with a proper full-size tire. Page 1878 Page 6169 Locations Number One Cylinder: Locations Seat Weight Pressure Sensor P0781 P0780 - P0784: Testing and Inspection P0781 4R70W For diagnosis of code P0781 refer to chart Part 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 8731 Locations View 151-28 Page 790 P0780 - P0784: Testing and Inspection P0782 4R70W For diagnosis of code P0782 refer to chart Part 6 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 6595 View 151-9 Page 8709 View 151-21 Page 1051 P1270 - P1274: Testing and Inspection P1273 OBD II - Base Gasoline For diagnosis of code P1273 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5093 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Item 6: Spark Plug Wire-to-Spark Plug Removal Note Page 7974 DVD Player: Service and Repair DIGITAL VERSATILE DISC (DVD) PLAYER REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: DVD Player Screws Removal Note 1. Open the video dispay door to access the screws. Item 2: DVD Player Removal Note 1. The DVD player assembly must be supported while disengaging the clips. Pull down on the sides of the DVD player to disengage the clips from the bracket. INSTALLATION 1. To install, reverse the removal procedure. Page 2247 View 151-19 Service Precautions Compressor Fitting HVAC: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Page 3605 Part 2 Page 724 P0740 - P0744: Testing and Inspection P0743 Torqshift For diagnosis of code P0743 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 1736 Traction Control - Short Duration Activation Steering Angle Sensor: All Technical Service Bulletins Traction Control - Short Duration Activation TSB 07-10-11 05/28/07 ADVANCED TRACTION CONTROL SYSTEM - SHORT DURATION ACTIVATION FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 06-21-8 to update the Service Procedure. ISSUE Some 2004-2007 Freestar and Monterey vehicles equipped with the Advance Trac system may exhibit short duration nuisance Advance Trac activations with no lights continuously illuminated on the vehicle's instrument cluster. A DTC code may not necessarily be stored in memory. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE If any DTC codes are present, follow normal diagnostic procedures in the Workshop Manual (WSM) prior to completing the Service Procedure. Verify the sensor or tone ring windows are free of dirt or oil contamination. 2004-2005 Model Year Vehicles 1. Install the Steering Wheel Angle (SWA) Sensor Kit using the Installation Procedure. 2006-2007 Model Year Vehicles 1. Install the SWA Kit using the Installation Procedure. If the SWA Kit has already been installed, then go to Step 2 and update the Advance Trac software. 2. Update the Advance Trac software by reprogramming the Advance Trac module using IDS release 48.12 patch 14 and higher or 49.1 patch 3 and higher. This new calibration is not included in the VCM 2007.5 DVD. Calibration files may also be obtained at the website. 3. After installing the SWA Kit and calibrating the anti-lock brake system (ABS) module, integral vehicle dynamics (IVD) calibration will need to be performed. Follow the scan tool directions for the calibration procedures. Installation Procedure NOTE TO PREVENT DAMAGE TO THE SENSOR INSTALL THE TONE RING FIRST. 1. Place the steering wheel in the straight-ahead position and remove the ignition key. 2. Rotate the steering wheel until the steering column locks into position. 3. Disconnect the SWA sensor electrical connector. 4. Remove the two (2) SWA sensor screws. Page 8829 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 3568 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 4 Trailer Tow Relay, Right Turn Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Right Turn Brake Booster Sensor View 151-3 Page 8149 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 8980 23. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Install the affected seat(s). 3. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 4. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 5. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 6. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 7. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 8. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 9. Install the coat hook near the LH C-pillar trim panel. 10. Install the LH C-pillar trim panel. 11. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 12. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 13. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 14. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 15. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 16. Install the RH D-pillar trim panel. 17. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 18. Through the glove compartment opening, connect the passenger air bag module electrical connector. 19. Close the glove compartment. 20. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 21. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 22. Close the steering wheel access door. 23. Reconnect the battery ground cable. 24. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Seats Not Removed VEHICLES WITH SAFETY CANOPIES AND SEAT SIDE AIR BAGS, SEATS NOT REMOVED DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Page 360 P0270 - P0274: Testing and Inspection P0274 For diagnosis of code P0274 refer to chart B1219-B1317 / P0182-P1272 Page 8967 Compass: Adjustments Compass Calibration With Message Center COMPASS CALIBRATION - WITH MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. Start the vehicle. 2. Press the RESET button until RESET FOR CAL is displayed in the message center display. 3. NOTE: To exit the calibration adjustment mode before carrying out a compass adjustment, press the INFO button. Press the RESET button until CIRCLE SLOWLY TO CAL is displayed in the message center display. 4. Slowly drive the vehicle in a circle no more than 5 times at no more than 5 km/h (3 mph) until CIRCLE SLOWLY TO CAL changes to CALIBRATION COMPLETED in the message center. Without Message Center COMPASS CALIBRATION - WITHOUT MESSAGE CENTER 1. NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map lamps, wipers, etc.) and make sure all doors are closed. Start the vehicle. 2. Locate the compass module at the base of the mirror. Press the button located on the compass sensor module gently until CAL is displayed in the compass display and release the button. 3. NOTE: To exit the CAL mode before carrying out a compass adjustment, turn the ignition switch to the OFF position. Press the button until CIRCLE SLOWLY is displayed in the compass display. 4. NOTE: If the CIRCLE SLOWLY display does not turn off after the vehicle has been driven in a circle no more than 5 times, demagnetize the vehicle and repeat the procedure. Slowly drive the vehicle in a circle no more than 5 times at no more than 5 km/h (3 mph) until CIRCLE SLOWLY changes to CAL in the compass display. P2195 P2195 - P2199: Testing and Inspection P2195 OBD II - Base Gasoline For diagnosis of code P2195 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P2195 refer to chart Page 2065 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Entertainment Systems - DVD Player Screen Latch Rattle DVD Player: All Technical Service Bulletins Entertainment Systems - DVD Player Screen Latch Rattle TSB 04-14-6 07/26/04 RATTLE FROM DVD SCREEN LATCH ASSEMBLY FORD: 2003-2005 Explorer LINCOLN: 2003-2005 Aviator MERCURY: 2003-2005 Mountaineer ISSUE Some 2003-2005 Explorer 4drlMountaineerlAviator vehicles equipped with a factory installed DVD player may exhibit a rattling noise coming from the flip down screen latch assembly. ACTION To repair, replace the DVD screen latch assembly. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IT IS NOT NECESSARY TO REMOVE THE DVD ASSEMBLY FROM THE VEHICLE DURING THIS REPAIR. NOTE NO TOOLS ARE REQUIRED FOR THIS REPAIR. 1. Position the DVD screen in the down position. 2. Gently pull the latch out from the bottom of the DVD screen. 3. Install the new latch, making sure that the latch is lined up with the grooves in the body of the screen and gently sliding the latch into place. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041406A Replace The DVD Screen 0.2 Hr. Latch Assembly DEALER CODING CONDITION BASIC PART NO. CODE 10E956 33 Page 6242 Page 929 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4231 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Recall 04V446000: Front Hub/Rotor/Bearing Replacement Wheel Bearing: Recalls Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 4111 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Door Lock Actuator, Left Front Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming Vehicles Without Safety Canopies and Seat Side Air Bags VEHICLES WITHOUT SAFETY CANOPIES AND SEAT SIDE AIR BAGS DEACTIVATION AND REACTIVATION PROCEDURE There are three deactivation and reactivation procedures - One of the procedures (for vehicles with safety canopies/seat side air bags) require removal of the front seat(s). This procedure will be used when diagnosing or repairing a seat side air bag concern. This procedure will also be used when diagnosing or repairing any in-seat or seat mounted component of a seat equipped with a seat side air bag. - The other two procedures (one for vehicles without safety canopies/seat side air bags, one for vehicles with safety canopies/seat side air bags) do not require front seat removal during the diagnostic and repair process. This procedure will be used when diagnosing or repairing a concern that is not related to a seat equipped with a seat side air bag. Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. Service and Repair Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Overhead Console Removal Note 1. The overhead console is held in place by spring clips located on the panel. Item 3: Parking Aid Switch Removal Note 1. Release the tabs and remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Page 6208 Service Precautions Rear Door Hinge: Service Precautions CAUTION: - For correct sliding door operation, it is critical that the door adjuster wedge and striker on the body pillar fit smoothly into the wedge pocket and latch in the power sliding door. If any of the adjustments are made, realignment of the striker may be necessary. - Do not swing the door open more than twenty-five degrees or damage to the other hinges may occur. Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's Engine Control Module: Customer Interest Engine Controls - Engine Knock/Ping/MIL/Misfire DTC's TSB 10-3-3 03/01/10 DAMAGED SPARK PLUG ELECTRODE/MIL DTC P030X FORD: 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 7-14-1 to update the vehicle model years covered, Service Procedure and Part List. ISSUE Some 2004-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC's) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) 3. Look for evidence of water contamination within the PCM (liquid water, rust, water stains or deposits). (Figure 2) a. If evidence of water is found, obtain a replacement PCM and remove its cover before continuing on to Step 4. Locations Service Port HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System, Part 1 ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 6129 Page 6745 Part 1 Of 3 Part 2 Of 3 Page 8134 Page 4305 Oxygen Sensor: Harness Locations View 151-6 Customer Safety Information Air Bag(s) Arming and Disarming: Customer Safety Information WARNING: - If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. - To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. Page 6587 Power Steering Pressure Switch: Description and Operation Power Steering Pressure Sensor POWER STEERING PRESSURE SENSOR Power Steering Pressure (PSP) Sensor The power steering pressure (PSP) sensor (Figure 46) monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM will change 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 transmission electronic pressure control (EPC) pressure during the increased engine load, for example during parking maneuvers. Page 3519 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 954 Inspection Page 7498 1. WARNING: Check the side air bag deployment chute and clips for damage. The deployment chute and clips must not be repaired. If there is any damage to the deployment chute or clips, the seat back trim cover and deployment chute must be installed new as a unit. Position the deployment chute and clips through the backrest foam pad. 2. WARNING: If the air bag deployment chute is not properly positioned and completely closed, the side air bag may not deploy properly. Position the air bag deployment chute. 1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side air bag module, pulling it around the outboard side of the seat back frame. 2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side air bag module from the inboard side of the seat back. 3. WARNING: If the air bag deployment chute is not properly positioned and completely closed, the side air bag may not deploy properly. Attach the deployment chute clips and hook and loop strips. The side air bag deployment chute must encircle the side air bag module, going completely around the side air bag module and the side of the seat back frame. - Align the side air bag deployment chute to the side air bag module, making sure it covers the length, but not the top or bottom, of the side air bag module. 4. Roll the seat backrest trim cover down and reattach the lower J-clips. - Make sure any necessary wire harnesses, connectors or ducts are through the trim cover openings. Item 16: Climate Control Seat Duct Installation Note Page 2418 Oxygen Sensor: Harness Locations View 151-6 Page 1295 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 613 B1219-B1317 / P0182-P1272 Note 5: Clear the DTC and retest. If the DTC is retrieved again, check for aftermarket performance products before replacing the AFCM. If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 953 P1150 - P1154: Testing and Inspection P1151 For diagnosis of code P1151 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The Generation II (Gen II) Torque Based Electronic Throttle Control (ETC) is a hardware and software strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes an electronic throttle body, the PCM and a accelerator pedal assembly to control throttle opening and engine torque. The ETC system basically replaces the standard cable operated accelerator pedal, idle air control (IAC) motor, 3-wire throttle position sensor (TPS) and mechanical throttle body Background "Why Torque Based ETC" 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: VCT (deliver same torque during transitions) - Hybrid Electric Vehicle (HEV) Torque based ETC also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: Eliminate cruise control actuators - Eliminate Idle Air Control (IAC) Bypass actuator - Better airflow range - Packaging (no cable) - More responsive powertrain at altitude and improved shift quality It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. Electronic Throttle Body (ETB) The Gen II electronic throttle body (Figure 133) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2 times stronger than the main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (48 Km). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to avoid the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle and idle quality and eliminates the need for IAC bypass actuator. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires four wires. 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, Page 8947 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 8646 2. Detach and disconnect the backrest TED electrical connector and disconnect the backrest climate controlled seat duct from the climate controlled blower for backrest removal. 3. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers attached to the seat cushion and pan assembly. Disconnect the heated seat cushion element electrical connectors from the backrest heated seat element. Item 17: Seat Track-to-Cushion Seat Pan Bolts Disassembly Note 1. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Remove the seat cushion pan bolts and remove the seat cushion assembly. Item 18: Seat Cushion Trim Cover Disassembly Note 1. Release the J-clips. 2. Remove all the seat cushion hog rings (two shown) and remove the seat cushion trim cover. ASSEMBLY 1. NOTE: Make sure the battery negative cable is still disconnected before continuing with the assembly portion of this procedure. To assemble, reverse the disassembly procedure. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat. 3. CAUTION: - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the vehicle has not been exposed to temperatures below 6°C (42°F) or above 36°C (97°F) within four hours prior to the rezeroing process. If the vehicle has been exposed to temperatures outside the temperature limits (6-36°C), the vehicle must be exposed and kept at a temperature within the limits for a minimum of four hours. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. Page 392 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7644 parts. This will reduce the risk of injury in the event of an accidental deployment. NOTE: All inoperative safety belt buckle pretensioners and safety belt retractor pretensioners have been placed on the Mandatory Return List. All damaged safety belt buckle pretensioners and safety belt retractor pretensioners must be treated the same as any inoperative live safety belt buckle pretensioner or safety belt retractor pretensioner being returned. 1. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 2. Package and return the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner to Ford Motor Company. Scrapped Vehicle SAFETY BELT PRETENSIONER DISPOSAL - UNDEPLOYED, SCRAPPED VEHICLE REMOTE DEPLOYMENT WARNING: - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the safety belt pretensioner is deployed, hearing protection is required. - Do not position the safety belt buckle pretensioner or safety belt retractor pretensioner so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. All vehicles 1. Remove the safety belt buckle pretensioner assembly from the vehicle. Safety belt buckle pretensioner without a hard-wired electrical connector 2. Cut and remove the safety belt buckle pretensioner electrical connector from the main seat wire harness, leaving about four inches of extra wire. 3. Attach the electrical connector to the safety belt buckle pretensioner. All vehicles 4. Strip the wires near the electrical connector. 5. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and attach one end of each wire to the safety belt buckle pretensioner wires. 6. Position the safety belt buckle pretensioner assembly on a flat surface in an open outdoor area so that moveable parts do not contact the support surface. 7. Remain at least 6.1 meters (20 feet) away from the safety belt buckle pretensioner assembly. Page 6628 Power Steering Fluid: Specifications Power Steering Fluid Type ................................................................................................................................... Motorcraft MERCON ATF XT-2-QDX Page 443 P0350 - P0354: Testing and Inspection P0354 For diagnosis of code P0354 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6693 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? P0053 P0050 - P0054: Testing and Inspection P0053 For diagnosis of code P0053 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9044 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 1906 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 723 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6977 Compressor Shaft Seal: Service Precautions CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor. Page 2518 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 7391 1. Route the clockspring wire harness down the side of the steering column and into the holders. 2. Connect the two clockspring electrical connectors and install the connectors onto the bracket. Item 4: Retaining Pin Installation Note 1. For vehicles receiving a new clockspring, remove the retaining pin. Item 5: Tape Installation Note 1. For vehicles reusing the clockspring that was removed, remove the tape. Page 7767 Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. Item 4: Quarter Trim Panel Removal Note 1. Pull out on the quarter trim panel at the C-pillar to release the retaining clips and access the C-pillar side impact sensor. - Separate the weatherstrip at the quarter trim panel. INSTALLATION Page 8417 connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Page 2085 Locations View 151-10 Page 5132 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Page 8122 Test W8-W10 Page 3749 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 2783 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 1448 P2110 - P2114: Testing and Inspection P2112 For diagnosis of code P2112 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagrams Page 9353 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 1576 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Driver Side Page 9618 Fresh/recirculation Door Actuator Page 4700 Symbols Part 2 Page 3625 Part 2 Of 2 4. Remove the parts in the order indicated in the illustrations and tables. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Item 7: Radiator Alignment Pins Removal Note 1. Tie the radiator and the condenser to the upper radiator support using mechanics wire. ^ Allow 2 inches of slack in the condenser wire to allow for movement. ^ Remove the radiator alignment pins. Item 13: Transmission Cooler Tubes Removal Note Service and Repair Sliding Door Window Glass: Service and Repair SLIDING DOOR WINDOW GLASS Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the rear door trim panel. Page 8349 Sliding Door Contact Switch, Right Door Position Switch: Locations Sliding Door Contact Switch, Right View 151-14 System Diagnosis P0320 - P0324: Testing and Inspection For diagnosis of code P0320 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1062 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7373 Part 2 Page 3289 1. If the valve tappets are to be reused, they must be installed in their original location. Mark the valve tappets for location before removing. Items 8-11: Valve Spring Removal Note 1. CAUTION: The piston must be at the top of its stroke with both the intake and exhaust valves closed prior to removing the valve spring. CAUTION: If a valve drops into the cylinder, remove the cylinder head. Hold the valve in the cylinder head. Remove the spark plug. - Apply a minimum of 689 kPa (100 psi) of compressed air into the cylinder. 2. Using the special tool, compress the valve springs. 3. Remove the following: 1. Valve spring retainer key 2. Valve spring retainer 3. Valve spring 4. Valve stem seal Item 8: Valve Spring Retainer Key Installation Note 1. CAUTION: Do not release the compressed air from the cylinder until after the valve spring keys are installed. After installing the valve spring keys, release the air pressure from the cylinder. Install the spark plug. Items 3-1: Rocker Arm Installation Note Page 8849 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 2: Speed Control Deactivator Switch Removal Note 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Remove the speed control deactivator switch. INSTALLATION 1. To install, reverse the removal procedure. Item 2: Speed Control Deactivator Switch Installation Note 1. After the deactivator switch is installed, it is necessary to bleed the brake system. Page 2137 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 9208 Symptom Chart Page 4175 Symbols Part 5 Page 1632 Radiator Cooling Fan Motor Relay: Testing and Inspection Engine Cooling Fan Relay 5 Page 9545 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 1746 Page 9316 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity With Auxiliary Heater ........................................................................................................................... .................................................. 16.0 qts (15.1 L) Without Auxiliary Hearet ........................................ ................................................................................................................................ 15.0 qts (14.2 L) Page 8597 Seat Memory Switch: Testing and Inspection SWITCH - MEMORY SET Memory Set Switch Remove the memory set switch. Measure the resistance between the indicated terminals while pressing the requested switches. The resistance should be less than 5 ohms for each switch position. If the resistance is not less than 5 ohms for each switch, install a new switch; otherwise, return to the calling Pinpoint Test. NOTE: Refer to Multimeter User's Manual for testing diodes. To check the memory set switch LED, connect the positive meter lead to terminal 7 and the negative lead to terminal 1. The meter should indicate greater than 0.3 volts. Reversing the leads, the meter should read OL. If the meter readings are not as indicated above, install a new switch; otherwise, return to the calling Pinpoint Test. Driver Memory Seat Horizontal Sensor Page 1415 P2065 - P2069: Testing and Inspection P2067 For diagnosis of code P2067 refer to NOTE 7: NOTE 7: Refer to Instrument Panels, Gauges and Warning Indicators, fuel level indicator or Rear Electronic Module (REM) diagnosis. See: Instrument Panel, Gauges and Warning Indicators/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9398 LH Front Parking/Turn Lamp C1115, RH Front Parking/Turn Lamp C1043 LH Side Marker C151, RH Side Marker C161 License Lamp C421 Page 9330 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 313 P0220 - P0224: Testing and Inspection P0223 For diagnosis of code P0223 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Removal and Installation Steering Gear: Service and Repair Removal and Installation Steering Gear Special Tool(s) NOTE: New Teflon seals must be installed any time the lines are disconnected from the steering gear. 1. CAUTION: When repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. CAUTION: Do not allow the steering wheel to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. Hold the steering wheel in the straight-ahead position using a suitable holding device. 2. Place the vehicle on a hoist. Make sure that the transmission is in NEUTRAL. Page 5985 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor NOTE: When installing a new steering wheel rotation sensor, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration procedures. 1. Remove the parts in the order indicated in the following illustration and table. Page 4681 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 6438 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 2483 Disclaimer Page 5256 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Removal and Installation 1. Remove the catalytic converter. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Locations Page 2390 Engine Temperature Sensor: Description and Operation The CHT sensor ^ sends the PCM a signal indicating cylinder head temperature. ^ resistance decreases as coolant temperature increases. Typical Cylinder Head Temperature (CHT) Sensor The cylinder head temperature (CHT) sensor (Figure 32) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and increases as temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in 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 cylinder head temperature (CHT) sensor is installed in the aluminum cylinder head and measures the metal temperature. The CHT sensor can provide complete engine temperature information and can be used to infer coolant temperature. If the CHT sensor conveys an overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on information from the CHT sensor. A cooling system failure such as low coolant or coolant loss could cause an overheating condition. As a result, damage to major engine components could occur. 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 details. Page 622 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1294 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P1711 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 773 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3116 Page 9559 Test X3-X6 Normal Operation The trailer tow relays are supplied power from the BEC. Ground for the trailer tow parking lamp relay is provided through circuit 576 (DG). Ground for the trailer tow LH turn lamp relay is provided through circuit 374 (DB/WH). Ground for the trailer tow RH turn lamp relay is provided through circuit 378 (BN/YE). Ground control for the trailer tow relay coils is controlled by the SJB. When the trailer tow parking lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 962 (BN/WH). When the trailer tow LH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 52 (YE). When the trailer tow RH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 64 (DG). Possible Causes - circuit 52 (YE) short to power - circuit 64 (DG) short to power - circuit 374 (DB/WH) short to ground - circuit 378 (BN/YE) short to ground - circuit 576 (DG) short to ground - circuit 962 (BN/WH) short to power - trailer tow relay - BEC - SJB Page 8051 Page 5791 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 [NEW] This supplement to 04S24 involves replacing both front wheel hubs and both front wheel rotors as separate components. The hub and rotor assembly kits that were offered when the Safety Recall was launched are no longer available. SERVICE PROCEDURE [NEW] 1.Replace both front wheel hubs and rotors. Refer to Section 204-00 of the 2004 Freestar/Monterey Workshop Manual found on the PTS website for the latest service procedures. Review the following notes during service: ^ Use new bolts, PN W705696-5436, when installing the new hubs. Tighten to 115 Nm (85 lb-ft). ^ When installing the rotor onto the hub, apply a light coating of High Temperature Nickel Anti-Seize Compound, XL-2, to the mating surfaces of the hub and rotor. DO NOT ALLOW ANY ANTI-SEIZE COMPOUND TO GET ONTO THE STUD BOLT THREADS. Make sure that the compound is free of any debris (dirt, rust, etc.) that could cause an excessive rotor run-out condition. ^ Be sure to reinstall any rotor-to-hub screws that were present during disassembly. Tighten screws to 28 Nm (21 lb-ft). ^ Apply a small patch of Threadlock 262, TA-26, to the last five (5) axle shaft joint threads before installing a new axle shaft nut. Tighten the nut to 130 Nm (96 lb-ft). Page 7214 In-Vehicle Temperature Sensor - EATC Page 9648 Front Door Window Motor: Service and Repair DOOR WINDOW MOTOR INITIALIZATION CAUTION: Make sure no obstructions are present in the window system when carrying out this procedure. NOTE: - Excessive bounce-back (bounce-back that occurs with no obstructions present) may indicate a non-initialized window motor. - The front window motors must be initialized whenever: the motor is removed from the window regulator, a new motor is installed, a new window regulator is installed, a new window glass is installed, a glass top run removal and installation and when carrying out any operation in which grease or lubricants are applied to the window system. A new front window motor will be in a proportional up/down mode until initialized. - All front window components (window glass, window regulator, window motor and glass top run) must be installed and tightened to specification before carrying out this procedure. - If this procedure is only partially completed, the front window motor will remain non-initialized and only the proportional up/down functions will operate. A non-initialized window motor may allow one-touch down operation, but will NOT allow one-touch up operation. - Steps 1 through 6 must be completed within 30 seconds. The entire procedure must be completed within five minutes. - Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire procedure is completed. - Steps 7 and 9 require the applicable front window control switch be held in the UP position until the front window motor stalls the window glass into the glass top run. Step 8 requires the applicable window control switch be momentarily actuated to the DOWN position. 1. Start with the ignition key in the OFF position with the applicable front door open. 2. Turn the ignition key to the ON position. 3. Press the applicable front window control switch to the AUTO position six times (AUTO up or AUTO down). 4. Turn the ignition key to the OFF position and make sure the front door is open. 5. Press the front window control switch to the AUTO position six times (AUTO up or AUTO down). 6. Turn the ignition key to the ON position and close the front door. The front window glass will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates the front window motor has entered initialization mode. 7. Press and hold the front window control switch to the UP position until the window glass stalls into the glass top run. 8. Momentarily press the front window control switch to the DOWN position and release. The window will carry out a one-touch down operation until the window glass stalls at the bottom of travel stop designed into the window regulator. 9. Press and hold the front window control switch to the UP position until the window glass stalls into the glass top run. Once this operation is complete, the front window glass will move up-down-up-down approximately 20 mm (0.8 in) indicating the front window motor has been successfully initialized. 10. Verify correct operation of the front window by carrying out a one-touch down, one-touch up, proportional down and proportional up operation. Page 2372 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 3719 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 8426 7. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 8. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies and seat side air bags 9. CAUTION: Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. If the safety canopy bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the safety canopy electrical connector, a low resistance fault will be generated by the RCM. 10. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. If the side air bag bridge resistor is removed, an open circuit fault will be generated by the restraints control module (RCM). If a restraint system diagnostic tool is installed at the side air bag floor electrical connector, a low resistance fault will be generated by the RCM. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 11. Remove the safety belt guide cover. Page 8027 Safety Belt System Seat Belt Tension Sensor: Description and Operation Safety Belt System SAFETY BELT TENSION SENSOR The safety belt tension sensor is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is located at the front passenger safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Page 1523 Page 337 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6559 NOTE THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP LENGTHS AND FOLDING TECHNIQUES. 2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4 mm) away from stripped end (Figure 6). Page 2486 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 421 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Accessory Delay Relay 1 Page 9551 Trailer Lamps: Pinpoint Tests BEC C1035a SJB C2280c Locations Blower Motor Switch: Locations View 151-8 P0532 P0530 - P0534: Testing and Inspection P0532 For diagnosis of code P0532 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9243 Page 6520 Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15 web site. To access on PTS: ^ Select the year/model of the vehicle on the P15 home page ^ Select the wiring tab ^ Select the link to the pigtail or terminal repair kit at the top right of screen. Additional service information contained in this TSB detailing wire folding, soldering, and crimping techniques may be helpful. ACTION REPAIR VS REPLACEMENT The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell connectors when available. The only exceptions to this procedure are when: ^ The repair cost exceeds the cost to replace the wiring harness ^ There are no component parts released to service the wiring harness RESTRAINTS RELATED WIRING REPAIRS If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford Motor Company publication. If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401, 14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits with gold plated terminals are also available in the parts catalog. Disclaimer Service Tips Refer to applicable model year wiring diagrams for circuit information. Twisted Wire Circuits For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51 mm) Twist the repaired wires in the same direction and with the same general twist rate as the original wiring. Reapply the shielding on shielded circuits. Page 9516 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 Page 5714 1. Disconnect the steering intermediate shaft upper bolt and position the shaft aside. Item 7: Brake Booster Nuts Removal Note 1. Position the brake booster forward enough to allow the brake booster studs to clear the brake pedal assembly. Item 11: Drive Cable Assembly Removal Note 1. Release the cable assembly from the motor and the transmissions. LH Side Rear Page 6159 Page 1039 B1219-B1317 / P0182-P1272 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3037 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Sliding Door Contact Switch, Right Door Position Switch: Diagrams Sliding Door Contact Switch, Right Page 14 P0010 - P0014: Testing and Inspection P0013 For diagnosis of code P0013 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9707 3. Using the special tool, distance the windshield from the body. 4. Remove the dual lock windshield glass stops from the sheet metal frame. 5. Using the special tool, cut the remaining urethane adhesive and remove the windshield. 6. Using a soft brush or vacuum, remove dirt and foreign material from the pinch weld. INSTALLATION 1. To install, reverse the removal procedure. Item 1: Windshield Glass Installation Note CAUTION: After installing the new windshield glass, the vehicle should not be driven until the urethane adhesive has cured. The curing time at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours. (Refer to the Essex drive away chart for the cure times as the temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond. 1. Dry fit the new windshield glass to the existing urethane bed on the body pinch weld. Align the windshield in the opening for uniform fit and adjust the setting blocks as needed for the best fit. 2. Use tape or non-permanent marking pencil to make alignment marks on the windshield (preferably at the setting blocks), and the body to aid in the installation alignment of the new windshield. 3. After alignment, remove the windshield glass and molding assemblies from the vehicle and place it on a stable work surface. 4. CAUTION: Care must be taken to avoid scratching the pinch weld. Trim the remaining urethane adhesive on the pinch weld. The urethane must be smooth and free of cuts and contamination after trimming. Avoid touching the urethane surface after preparation. 5. CAUTION: All rust found on the pinch weld must be removed and the pinch weld restored to OEM specifications. If surface rust is found, remove completely down to clean, bare metal. Prime pinch weld metal with an OEM-recommended curing automotive paint primer and allow to cure. If rust has penetrated through the pinch weld metal, repair the pinch weld sheet metal at a body shop before proceeding. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that may cause glass breakage. Clean or repair surface as necessary. 6. Use a wool applicator to apply urethane metal primer to any exposed metal on the pinch weld. Allow six to ten minutes to dry. 7. Clean the inside of the glass surface with an alcohol-free cleaner to make sure the ceramic-coated area is clean. 8. NOTE: If the moulding is already on the windshield glass, proceed to the next step. Align the "V" notch in the ceramic paint and windshield outside molding at top center. Fully seat the windshield outside molding along the top edge of the windshield glass and along the sides and bottom edges of the windshield glass. Locations View 151-10 Page 3909 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR Heated Oxygen Sensor (HO2S) The heated oxygen sensor (HO2S) (Figure 38) 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 temperatures of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater and the PCM will turn on the heater by providing the ground when the proper conditions occur. Since model year 1998 a high power HO2S heater and heater control system have been installed on the Stream 1 HO2S sensors of most vehicles. The high power heater reaches closed loop fuel control temperatures faster, which allows closed loop engine operation sooner. The use of this heater requires that the HO2S heater control be duty cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style 3.3 ohm heater. Service and Repair Fan Blade: Service and Repair REMOVAL AND INSTALLATION Radiator, Cooling Fan and Shroud Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the transmission fluid cooler. Part 1 Of 2 Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Page 9596 Page 6349 Fuse Block: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 6305 Disclaimer Page 7591 12. Remove the safety belt guide bolt and safety belt guide. 13. Remove the screws and attachments. 14. Remove the D-pillar trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the D-pillar trim panel. 3 Remove the D-pillar trim panel. 15. Disconnect the passenger side safety canopy module electrical connector. Page 7223 Page 2673 View 151-9 Page 7375 Special Tool(s) Page 71 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8957 Symptom Chart Electronic Automatic Temperature Control (EATC) Module Control Module HVAC: Diagrams Electronic Automatic Temperature Control (EATC) Module Page 1880 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 7473 6. NOTE: When installing an occupant classification sensor service kit, the main seat wire harness pressure sensor electrical connector does not get used. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. 2 Slide the electronic control unit (ECU) into the seat cushion pan bracket. The ECU must be correctly positioned and securely fastened in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). 3 Install the rivets. 4 Connect the main seat wire harness occupant classification sensor electrical connector to the service part occupant classification sensor electrical connector. 5 Tie-strap the unused main seat wire harness pressure sensor electrical connector safely out of the way. 6 Tie-strap all loose wire harnesses and electrical connectors safely out of the way. Item 4: Connector Installation Note 1. If equipped, connect and install the electrical connectors and wire harnesses to the seat cushion pan. Item 7: Climate Control Seat Duct Installation Note 1. If equipped, connect the climate control duct and the backrest thermal electric device electrical connector. 2. If equipped, connect the two seat cushion heated seat element electrical connectors. Item 8: Side Air Bag Module Connector Installation Note 1. If equipped, route the side air bag module wire harness and electrical connector and attach to the seat riser and cushion pan. Page 2011 View 151-13 Page 220 Inspection Page 4143 Page 1876 Page 1423 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Brakes - Rear Caliper Leaks (Mexico Vehicles Only) Brake Caliper: Customer Interest Brakes - Rear Caliper Leaks (Mexico Vehicles Only) TSB 06-14-11 07/24/06 REAR BRAKE CALIPER LEAKS (VEHICLES SOLD IN MEXICO ONLY) - SERVICE TIP FORD: 2004-2006 Freestar MERCURY: 2004-2006 Monterey ISSUE 2004-2006 Freestar / Monterey vehicles may exhibit rear brake caliper fluid leaks - Service Tip. ACTION The rear brake caliper fluid leaks could be fluid seepage that may occur under certain conditions. Wetness around the piston seal is acceptable and should merely be wiped clean without any required repairs. SERVICE PROCEDURE If fluid accumulates enough that it causes dripping, then replace the brake caliper with the part that has been recently updated in service. Refer to Workshop Manual, Section 206-04, Rear Disc Brake. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 1109 07 Disclaimer Front Seat Cushion Seat Cushion: Service and Repair Front Seat Cushion Driver FRONT SEAT CUSHION - DRIVER Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. NOTE: If a side air bag deployment took place, the seatback pad, trim cover and side air bag module must be replaced. The seatback frame should be replaced if necessary. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. Page 9695 Apply a bead of urethane adhesive to the sliding door glass on the primed area. 8. CAUTION: Open the windows to prevent the sliding door glass from being pushed out by the air pressure if the door is closed. Install the sliding door window glass. 9. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. Page 7753 Page 6338 Fuse: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Description and Operation Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING SYSTEM Overview Variable Cam Timing (VCT) enables rotation of the camshaft(s) relative to the crankshaft (phase-shafting) as a function of engine operating conditions. There are four 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 four operational modes; idle, part throttle, wide open throttle and default mode. At idle and low engine speeds with closed throttle, the phase angle are controlled by air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM controls cam timing 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 improve torque. In addition, on some applications a VCT system can eliminated the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Currently for the 2004 model year, Ford Motor Company uses the PS and DEPS systems. The IPS system is on Lincoln LS, Thunderbird and Focus SVT and the DEPS system is on the F150 5.4L 3V. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (camshaft position sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (crankshaft position sensor) provides the PCM with crankshaft positioning information in 10 degree increments (Figure 115). 1. The PCM receives input signals from the IAT (intake air temperature), ECT (engine coolant temperature), EOT (engine oil temperature), CMP, TP (throttle position), MAF (mass air flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper 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 Page 4711 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. Page 5001 INSTALLATION 1. To install, reverse the removal procedure. 2. Fill and bleed the cooling system. Item 11: Camshaft Synchronizer Installation Note 1. CAUTION: - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature. 2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine. Description and Operation Catalytic Converter: Description and Operation CATALYST AND EXHAUST SYSTEMS Overview V-Engines In-Line Engines 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 vapor (H2O). However, it also contains carbon monoxide (CO), oxides of nitrogen (NOx), hydrogen (H), and various unburned hydrocarbons (HCs). CO, NOx, and HCs are major air pollutants, 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 will be used between the front and rear exhaust pipes. Catalytic converter efficiency is monitored by the On Board Diagnostic (OBD) system strategy in the PCM. Refer to the Catalyst Efficiency Monitor-Federal Test Procedure at the beginning of Description and Operation for specific OBD catalyst monitor information. The number of HO2S(s) used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV, ULEV, PZEV). Refer to (Figure 121) and (Figure 122) for typical HO2S stream locations and naming convention. On most vehicles only two HO2S are used in an exhaust stream. The front sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control while the ones after the catalyst (HO2S12/HO2S22) will be utilized to monitor catalyst efficiency. However, some Partial Zero Emission Vehicles (PZEV) will utilize three HO2S sensors for each engine bank. The stream 1 sensors (HO2S11/HO2S21) before the catalyst will be used for primary fuel control, the next group of sensors or stream 2 (HO2S12/HO2S22) is utilized to monitor the light-off catalyst and the last group of sensors or stream 3 (HO2S13/HO2S23) is utilized for long term fuel trim control to optimize catalyst efficiency (Fore Aft Oxygen Sensor Control). Currently Ford's PZEV vehicles use only a Page 6658 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer P1500 P1500 - P1504: Testing and Inspection P1500 For diagnosis of code P1500 refer to chart P1479-P1640 NOTE 6: Go to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 9709 Special Tool(s) Description and Operation Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITORING SYSTEM (TPMS) Your vehicle may have a temporary spare tire. The temporary spare tire for your vehicle is labeled as such. It is smaller than a regular tire and is designed for emergency use only. Replace this tire with a full-size tire as soon as possible. Note: The Low Tire Pressure Warning system (if equipped) will detect the temporary spare tire and illuminate the low tire warning light until the spare tire is replaced with a proper full-size tire. Page 676 P0715 - P0719: Testing and Inspection P0718 Torqshift For diagnosis of code P0718 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 181 Inspection Page 1688 Horn Relay: Testing and Inspection Page 2014 View 151-20 Service and Repair Stabilizer Link: Service and Repair Stabilizer Bar and Link - Front NOTE: Use the hex holding feature to prevent the studs from turning while removing or installing the stabilizer bar link nuts. 1. With the vehicle in NEUTRAL, position on a hoist. Part 1 Of 3 Part 2 Of 3 Brakes - Accelerated rear Brake Pad Wear Brake Rotor/Disc: All Technical Service Bulletins Brakes - Accelerated rear Brake Pad Wear TSB 04-26-10 12/31/04 REAR BRAKE LINING ACCELERATED WEAR FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles may exhibit accelerated rear brake pad lining wear, heavily scored rear rotors, or metal pickup in the rear lining. ACTION Replace the rear brake pad linings, machine the rotors as required. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042610A 2004-2005 0.7 Hr. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads Only 042610B 2004-2005 1.6 Hrs. Freestar/Monterey: Inspect, Measure And Replace Rear Brake Pads, Machine Both Rear Brake Rotors On Vehicle DEALER CODING CONDITION BASIC PART NO. CODE 2200 42 Disclaimer Page 9001 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Rear View 151-26 Page 2725 Locations View 151-17 Page 9569 Page 4712 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Body - Cowl Panel Grille Breakage Cowl: Customer Interest Body - Cowl Panel Grille Breakage TSB 04-17-6 09/06/04 COWL PANEL GRILL BREAKING FORD: 1999-2003 Windstar 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 1999-2003 Windstar and 2004-2005 Freestar/Monterey vehicles may exhibit the windshield cowl panel grille (leaf screen) breaking at the grille opening. ACTION To service, replace cowl panel with updated service part. Refer to Workshop Manual Section 501-02. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041706A Replace The 0.3 Hr. Windshield Cowl Panel Grille (Leaf Screen) DEALER CODING CONDITION BASIC PART NO. CODE 70022A68 01 Disclaimer Page 9515 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 136 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4559 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 4734 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 1358 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8256 1. Remove the rivet. Item 14: Rivet Removal Note 1. Remove the interior sliding door handle. - Remove the rivets and slide the interior handle forward. INSTALLATION 1. To install, reverse the removal procedure. Item 14: Rivet Installation Note 1. Using the special tool, install the new rivets. Item 12: Rivet Installation Note Page 7137 Refrigerant: Service and Repair Identifying Refrigerants IDENTIFYING REFRIGERANTS Refrigerant Identifier With Air-Radicator SPECIAL TOOL(S) Refrigerant Identification 1. NOTE: An A/C refrigerant analyzer 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 identifier to obtain the sample for testing. 2. The diagnostic tool will display one of the following: - If the purity level of R-134a is 98% or greater by weight, the green "PASS" light emitting diode (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 diagnostic tool 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 diagnostic tool has determined that a refrigerant source is pure (R-134a is 98% or greater by weight) and air concentration levels are 2% or greater by weight, the diagnostic tool 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. Page 7416 Page 4459 Camshaft Position Sensor: Service Precautions CAUTION: - Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. - After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from top dead center (TDC) of the compression on the No. 1 cylinder. - A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. - It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure. Page 5291 Item 3: Transmission Fluid Cooler Tubes (at Radiator) Removal Note 1. Using the special tool, disconnect the fluid cooler tubes from the fittings at the radiator. Item 2: Transmission Fluid Cooler Tubes (at Transaxle) Installation Note 1. Insert the tubes in the transaxle fittings to seat the retaining tabs. Slightly pull back on the tubes to make sure that the tubes are locked. Page 6136 Page 7611 Child Seat Tether Attachment: Technician Safety Information WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters (if so equipped), child safety seat tether attachments and attaching hardware should be inspected after any collision. All belt assemblies should be installed new unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and installed new if either damage or improper operation is noted. ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 2820 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 9520 Tail Lamp: 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. 92-1 Page 6870 View 151-8 Page 930 P1125 - P1129: Testing and Inspection P1129 For diagnosis of code P1129 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 689 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0721 refer to chart Page 3036 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Auxiliary Blower Motor Relay Blower Motor Relay: Testing and Inspection Auxiliary Blower Motor Relay Page 9587 Page 4314 Locations View 151-16 Page 2008 View 151-20 Page 7936 Page 1527 Accessory Delay Relay: Testing and Inspection Accessory Delay Relay 2 OBD II - Base Gasoline P0175 - P0179: Testing and Inspection OBD II - Base Gasoline For diagnosis of code P0175 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6185 Page 2960 Fluid - A/T: Service and Repair Check Fluid Level and Condition Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level indicator shows the fluid below the DO NOT DRIVE mark or internal failure could result. If the vehicle has been operated for an extended period of time at highway speeds, in city traffic, in hot weather or while pulling a trailer, the fluid needs to cool down to obtain an accurate reading. The fluid level reading on the fluid level indicator will differ depending on operating and ambient temperatures. The correct reading should be within the normal operating temperature range. Fluid Level Check Under normal circumstances the fluid level should be checked during normal maintenance. If the transaxle starts to slip, shifts slowly, or shows signs of fluid leaking, the fluid level should be checked. 1. With the transaxle in (P) PARK, the engine at idle, foot pressed on the brake, move the selector lever through each gear and allow engagement of each gear. Place the selector lever in the PARK position. 2. Wipe the fluid level indicator cap and remove the fluid level indicator. 3. Wipe the fluid level indicator with a clean cloth. 4. Install the fluid level indicator back in the fluid filler tube until it is fully seated, then remove the indicator. The fluid level should be within the normal operating range. High Fluid Level A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating internal parts. This will cause erratic control pressure, foaming, loss of fluid from the vent tube, and possible transaxle malfunction and/or damage. If an overfill reading is indicated, refer to Transmission Fluid Drain and Refill. See: Transmission Fluid Drain and Refill Low Fluid Level A low 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 Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transaxle malfunction and/or damage. If fluid needs to be added, add fluid in 0.25 Liters (1/2 pint) increments through the filler tube. Do not overfill the fluid. For fluid type, refer to the specification chart. Fluid Condition Check 1. Check the fluid level. 2. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or black or have a burnt odor. 3. Hold the fluid level indicator over a white facial tissue and allow the 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 the stain is a foamy pink color this may indicate coolant in the transaxle. The engine cooling system should also be inspected at this time. Testing and Inspection Micro ISO Relay: Testing and Inspection Service and Repair Air Cleaner Housing: Service and Repair AIR CLEANER ASSEMBLY REMOVAL 1. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Air Cleaner Cover Removal Note 1. NOTE: No tools are needed to remove the air cleaner cover. Removal should be carried out using hands only. Release the clamps and separate the air cleaner cover from the air cleaner tray. INSTALLATION 1. To install, reverse the removal procedure. Locations Positive Crankcase Ventilation Valve: Locations PCV Valve Recall 04V446000: Front Hub/Rotor/Bearing Replacement Brake Rotor/Disc: Recalls Recall 04V446000: Front Hub/Rotor/Bearing Replacement Make / Models : Model/Build Years: Ford / Freestar 2004 Mercury / Monterey 2004 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID Number : 04V446000 Recall Date : SEP 09, 2004 COMPONENT: Wheels: Cap/Cover/Hub Potential Number Of Units Affected : 34013 SUMMARY: Certain minivans may have been produced with front wheel hub assemblies that were not heat treated correctly. This condition may lead to the development of small cracks in the hub. CONSEQUENCE: If the cracks were to progress, this could eventually result in wheel separation. wheel separation may lead to loss of vehicle control, and potentially result in a vehicle crash. REMEDY: Dealers will replace the front hub, rotors, and wheel bearings. The recall began September 20, 2004. Owners should contact Ford at 1-800-392-3673. NOTES: Ford Recall NO. 04S24. Customers can also contact The National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Page 5993 View 151-4 Page 815 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4034 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Page 8233 3. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Rivet Removal Note 1. Connect the window control switch. 2. Connect the battery. Page 1477 P0603-P2198 / U0309-U2015 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4351 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION SWITCH Clutch Pedal Position (CPP) Switch The clutch pedal position (CPP) switch (Figure 30) is an input to the PCM indicating the clutch pedal position. The PCM provides a 5-volt reference (VREF) signal to the CPP switch. If the CPP switch is closed, indicating the clutch pedal is engaged, the output voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1 volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch is open, meaning the clutch pedal is disengaged, the input on the CPP signal to the PCM will be approximately 5 volts. Then, the 5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load information in mass air flow and fuel calculations. Page 5012 3. If removing the ignition coil, remove the wiper motor and pivot assembly. 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Page 2351 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 5996 Page 9015 Page 1913 Air Bag Control Module: Technician Safety Information WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged SRS components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. - The tightening torque of the air bag restraints control module (RCM) retaining bolts is critical for correct system operation. Page 9396 Symptom Chart Page 4421 View 151-5 Master Window/Door Lock/Unlock Switch View 151-18 Page 3094 Page 8579 Seat Heater Control Module: Diagrams Climate Controlled Seat Module, Passenger Side Page 4399 Engine Control Module: Description and Operation POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO) The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem generates vehicle speed information for distribution to the vehicle's electrical/electronic modules and subsystems that require vehicle speed data. This subsystem senses the transmission output shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired signal or as a message on the vehicle communication network (SCP or HS-CAN). The key features of the PCM-VSO system are to: - Infer vehicle movement from the output shaft sensor signal - Convert transmission output shaft rotational information to vehicle speed information - Compensate for tire size and axle ratio with a programmed calibration variable - Utilize a transfer case sensor for four wheel drive applications - Distribute vehicle speed information as a multiplexed message and/or an analog signal The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and distance traveled information to all the vehicle speed signal users on the vehicle. VSO information can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM, or by Speed and Odometer data message via the vehicle communication network data link. The VSO hard -wired signal wave form is a DC square wave with a voltage level of 0 to VBAT. Typical output operating range is 2.22 Hz per MPH (1.3808 Hz per 1 km/h). Page 3870 Page 8559 Power Sliding Door Module: Diagrams RH Side Testing and Inspection Mini ISO Relay: Testing and Inspection System Diagnosis P0445 - P0449: Testing and Inspection For diagnosis of code P0446 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9184 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 2166 Page 8418 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Page 1203 Inspection Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 5873 Part 2 Of 2 Service Precautions Evaporative Canister Filter: Service Precautions WARNING: - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions can result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. Page 8037 Parking Assist Control Module: Diagrams Page 6675 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. Service and Repair Trunk / Liftgate Handle: Service and Repair LIFTGATE RELEASE HANDLE REMOVAL 1. Remove the license plate housing. 2. Remove the parts in the order indicated in the illustration and table. Item 4: Liftgate Latch Removal Note 1. Disconnect the liftgate actuating cable from latch. INSTALLATION 1. To install, reverse the removal procedure. Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Diagram Information and Instructions Brake Pedal Assy: Diagram Information and Instructions How To Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, 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. How To Navigate Between Wiring Diagrams Page 5044 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 5400 Wheel Bearing: Service and Repair Wheel Bearing, Wheel Hub, Wheel Knuckle, and Lower Arm - Front Special Tool(s) CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed. Do not use a new part of lesser quality or of a substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut from ball joints and stabilizer bar links. 1. Remove the front brake disc. Safety Belt Pretensioner Disposal - Deployed Seat Belt Tensioner: Service and Repair Safety Belt Pretensioner Disposal - Deployed SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED 1. WARNING: The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Page 4059 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 3665 Part 1 Of 4 Part 2 Of 4 Part 3 Of 4 ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Electronic Brake Control Module: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 3095 Fuse Block: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Engine Cooling Fan Relay 1 Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 2505 Inertia Fuel Shutoff Switch: Service Precautions WARNING: If you smell natural gas at any time other than during fueling, do not reset the IFS switch. Page 3117 Page 4508 View 151-4 Page 2978 Refrigerant: Service Precautions CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant into R-134a recovery/recycling equipment. Page 4905 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Powertrain Control Module (PCM) Reset Engine Control Module: Service and Repair Powertrain Control Module (PCM) Reset POWERTRAIN CONTROL MODULE (PCM) RESET Description All OBD II scan tools support the powertrain control module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. For more information about a drive cycle, refer to Drive Cycles. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Drive Cycles The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. Resetting Keep Alive Memory (KAM) Resetting Keep Alive Memory will return PCM memory to its default setting. Adaptive learning contents such as idle speed, refueling event, and fuel trim are included. A PCM Reset (described above) is also part of a KAM Reset. Both can be useful in post repair retest. After Keep Alive Memory has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. This function may not be supported by all scan tools. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Page 4085 Parts Block NOTE THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051611A Install Teflon Tape B 0.8 Hr. Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary) 051611B Install Teflon Tape C 1.1 Hrs. Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary) DEALER CODING CONDITION BASIC PART NO. CODE 70611B08 42 Disclaimer Page 9057 4. Connect the driver seat side air bag module electrical connector. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 6. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 7. Position the coat hook and install the screw. Forward Crash Sensor View 151-1 Page 1814 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 2481 NOTE THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART CONTAINED IN THIS TSB SHOWS THE ESM'S MAP SENSOR VOLTAGE CORRESPONDING TO A BARO READING IN INCHES OF MERCURY (IN-HG) AND IN HERTZ (HZ). THE CONVERSION TO KILO PASCALS (KPA) AND POUNDS PER SQUARE INCHES (PSI) ARE ALSO PROVIDED IN THE CHART. The ESM calculates EGR delta pressure using two (2) MAP sensors that independently read intake manifold and exhaust pressure. This allows vehicles with an ESM to use a MAP sensor to obtain a BARO reading from the intake manifold, prior to engine start. There are three (3) ways for the BARO PID to update in vehicles equipped with an ESM: 1. BARO is adjusted to a value based on the ESM's MAP sensor reading during key-on prior to engine start. There must be a minimum of 1 minute Page 8038 Page 6147 Page 9666 Page 794 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0783 refer to chart If there is no link in the chart then: Page 9231 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOPLAMP REMOVAL 1. Remove the liftgate trim panel. Page 1511 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Diagrams Power Trunk / Liftgate Control Module: Diagrams Page 8108 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 Page 2812 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 5423 Item 3: Crankshaft Rear Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation. Assemble the special tools and the crankshaft rear seal. 3. Install the special tools on the rear of the crankshaft. 4. Install the crankshaft rear seal. Tighten the center jack screw until the spacer contacts the engine block. Page 1607 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 4507 View 151-5 Page 9446 Page 321 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Specifications Water Pump Torque Sequence Page 2981 Special Tool(s), Part 2 SPECIAL TOOL(S) Fluorescent Dye Detection NOTE: Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line, and fitting in the refrigerant system for a leak. 1. Check for leaks using a Rotunda approved UV lamp. - Inspect all components, lines, and fittings of the refrigerant system. 2. If a leak is found, recover the refrigerant. 3. Repair the refrigerant system leak(s). 4. Evacuate and charge the refrigerant system. 5. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent. 6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda approved UV lamp. Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector NOTE: - Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda Service Precautions Fuel Pressure Release: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. Page 1785 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 7496 Part 2 1. WARNING: Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced (cleaning is permissible). NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag module is to be reused then reuse the side air bag module nuts. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Install the seat on the side with the affected side air bag. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 4. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure Page 8289 Page 9755 1. Remove the screws and remove the RH corner lamp. INSTALLATION 1. To install, reverse the removal procedure. Item 4: Windshield Washer Reservoir Installation Note 1. Position the windshield washer reservoir filler neck through the inner frame support. Item 2: Windshield Washer Hoses Installation Note 1. Connect the windshield washer hoses to the windshield washer reservoir before installation. Page 6568 Part 1 Of 2 Part 2 Of 2 Front Ride Height Measurement Part 1 Of 2 Page 9451 Page 6344 Fuse: Application and ID Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 2526 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Gap Spark Plug: Specifications Gap Spark Plug Gap.................................................................................................................................... ...................................... 1.3-1.4 mm (0.052-0.056 in) Page 3437 CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the generator. 3. Remove the coolant pump. 4. Remove the camshaft synchronizer. 5. Remove the parts in the order indicated in the illustrations and tables. Part 1 Of 3 Part 2 Of 3 Page 56 Inspection Page 222 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0182 refer to chart Page 8892 Page 9305 Horn Relay: Testing and Inspection Page 1989 Page 722 P0740 - P0744: Testing and Inspection P0742 For diagnosis of code P0742 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: Page 8983 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 3788 Page 1430 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8073 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 6489 Relay Box: Diagrams Smart Junction Box (SJB) Page 8439 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Locations View 151-5 Page 4374 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 825 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Torqshift For diagnosis of code P0960 refer to chart Page 4373 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 8771 Page 7515 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Page 2628 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustrations and tables. Item 1: Recliner Handle Cover Removal Note P0020 P0020 - P0024: Testing and Inspection P0020 For diagnosis of code P0020 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P1120 P1120 - P1124: Testing and Inspection P1120 For diagnosis of code P1120 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Service Precautions Fuel Temperature Sensor: Service Precautions WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. Page 3699 Electronic Throttle Monitor Operation, Part 1 Electronic Throttle Monitor Operation, Part 2 Accelerator and Throttle Position Sensor Inputs Accelerator Pedal Position Sensor Check Accelerator Pedal Position Sensor Check: Throttle Position Sensor Check Throttle Position Sensor Check: Throttle Plate Position Controller (TPPC) Outputs Page 416 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4816 2. Close and push the special tool into the open side of the cage. 3. Separate the fuel tube fitting. 4. Remove the special tool. Item 8: O-Ring Seal Removal Note CAUTION: 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. 1. Install new O-ring seals. INSTALLATION 1. To install, reverse the removal procedure. Page 219 P0180 - P0184: Testing and Inspection P0181 For diagnosis of code P0181 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 9637 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Page 8118 Trailer Tow C439 (4-pin Connector) Trailer Tow Parking Lamp Relay C1199, Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188 Test W Page 9400 Test O1-O3 P0171 P0170 - P0174: Testing and Inspection P0171 OBD II - Base Gasoline For diagnosis of code P0171 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 792 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3113 Page 6209 Page 8642 ASSEMBLY 1. To assemble, reverse the disassembly procedure. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Install the driver seat. 3. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Reactivate the supplemental restraint system (SRS). 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). Passenger FRONT SEAT CUSHION - PASSENGER Special Tool(s) SPECIAL TOOL(S) DISASSEMBLY WARNING: The safety belt pretensioner is a pyrotechnic device. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. CAUTION: If replacing only the front passenger seat cushion trim cover, the occupant classification sensor must be rezeroed. Locations View 151-8 Electrical - ABS/TCS/Park Brake Lamps Flickering Parking Brake Warning Lamp: All Technical Service Bulletins Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 200 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0172 refer to chart Page 110 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS Special Tool(s) SPECIAL TOOL(S) REMOVAL 1. Remove the rear window wiper and motor. 2. Remove the parts in the order indicated in the illustration and table. Item 1: Liftgate Window Glass Removal Note 1. Remove the rear wiper motor. Page 6317 3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice (Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles together until the ratchet releases, then allow the jaws of the tool to open fully. 4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to place the brazed seam of the butt splice toward the indenter (Figure 8). 5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the butt splice. Page 3240 Part 2 Of 2 To remove individual parts, only carry out the listed steps: 4. To install, reverse the removal procedure. Items 1-3: Rocker Arm Removal Note 1. If the rocker arms are to be reused, they must be installed in their original location. Mark the rocker arms for location before removing. 2. If removing valve springs, rotate the crankshaft until the piston is at the top of its stroke with both the intake and exhaust valves closed prior to removing the rocker arm. Item 7: Valve Tappet Removal Note Page 2213 View 151-12 Page 4597 Canister Purge Control Valve: Description and Operation EVAP CANISTER PURGE VALVE EVAP Canister Purge Valve Electronic EVAP Canister Purge Valve The EVAP canister purge valve (Figure 101) is part of the Enhanced EVAP system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the EVAP canister to the intake manifold during various engine operating modes. The EVAP canister purge valve is normally closed valve. The electronic EVAP canister purge valve (Figure 102) controls the flow of vapors electronically by way of a solenoid thereby, eliminating the need for an electronic vacuum regulator and vacuum diaphragm. The PCM outputs a signal between 0% and 100% duty cycle to control the EVAP canister purge valve. On applications with Electronic EVAP canister purge valve, the PCM outputs a signal between 0 mA and 1000 mA to control the solenoid. Page 9620 ABS - Module Replacement Service Tip Steering Angle Sensor: Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 7769 (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 2487 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Output Shaft Speed (OSS) Sensor Page 2619 Part 1 Part 2 Page 1724 Power Distribution Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 1344 P1750 - P1754: Testing and Inspection P1754 For diagnosis of code P1754 refer to chart Part 7 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle Page 1919 1. Pull out to release the retaining clips. - If equipped, disconnect the electrical connectors necessary for removal. Item 3: Large Electrical Connector Removal Note 1. Disconnect the large restraints control module (RCM) electrical connector. 1 Pinch the thumb tab and pivot the connector position assurance lever all the way back until it stops. 2 Pull out and disconnect the RCM electrical connector. INSTALLATION 1. To install, reverse the removal procedure. 2. Connect the battery ground cable. 3. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 4. Disconnect the battery ground cable and wait at least one minute. 5. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 6. Connect the battery ground cable. 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure Item 3: Large Electrical Connector Installation Note Heated Seat Module, Passenger Side Front Page 4033 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 1901 Page 8974 Air Bag(s) Arming and Disarming: Vehicle Damage Warnings CAUTION: - Do not deactivate the safety canopy module circuit by removing the safety canopy bridge resistor from the safety canopy electrical connector. - Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag floor electrical connector. Page 3499 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE Page 1650 Blower Motor Relay: Testing and Inspection Front blower motor relay Page 7479 View 151-15 Page 3953 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Tube Mounted Differential Pressure Feedback EGR Sensor The tube mounted differential pressure feedback EGR sensor (Figure 91) is identical in operation as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the underside of the sensor. Locations View 151-15 Page 6881 Air Door Actuator / Motor: Description and Operation Electronic Automatic Temperature Control TEMPERATURE BLEND DOOR ACTUATOR(S) The temperature blend door actuator(s): - are located on the heater core and evaporator core housing. - moves the temperature blend door(s) on command from the EATC module. - contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend door(s). - applies a 5 volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EATC module and is matched with an expected wiper voltage value. The EATC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EATC module wiper voltage value. MODE DOOR ACTUATORS The two mode door actuators: - include the air inlet door and defrost/panel/floor mode door actuators. - position the plenum doors to direct system airflow to the vehicle interior as determined by the EATC module settings. - contains a reversible electric motor - (defrost/panel/floor mode door actuator only) contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door. - (defrost/panel/floor mode door actuator only) apply a 5 volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EATC module and is matched with an expected wiper voltage value. The EATC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EATC module wiper voltage value. Page 2746 Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 7826 Locations View 151-6 Page 8247 3. Remove the parts in the order indicated in the illustration and table. To remove individual components, only carry out the listed steps. 4. To install, reverse the removal procedure. Item 1: Rivet Removal Note 1. Connect the window control switch. 2. Connect the battery. P0715 P0715 - P0719: Testing and Inspection P0715 Torqshift For diagnosis of code P0715 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 480 Inspection Door Ajar Switch, Left Front View 151-18 Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Page 6979 2. Remove the A/C clutch disc and hub retaining bolt. 1 Hold the A/C clutch disc and hub with the special tool. 2 Remove the bolt. 3. Remove the A/C clutch disc and hub and the A/C clutch disc and hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch disc and hub to force it from the compressor shaft. 2 Lift the A/C clutch disc and hub and the A/C clutch disc and hub spacer from the compressor shaft. 4. Remove the shaft seal felt from the nose of the A/C compressor with the special tool. 5. Clean the compressor nose area. 6. Insert the tip of the special tool into one of the snap ring eyes. Page 6523 Page 8913 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 5571 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 3884 Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are two design types of IAT sensors used, a stand alone\non-integrated type (Figure 39) and a integrated (Figure 40) 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. However, one is located before the supercharger at the air cleaner for standard OBD II/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Currently two types of IAT2 sensors are used. A non-integrated screw in type (Figure 39) and an integrated type, which is part of the Thermal Manifold Absolute Pressure (TMAP) sensor (Figure 48). The TMAP sensor consists of a IAT thermistor and a manifold absolute pressure (MAP) sensor. The thermistor portion of the TMAP is used for IAT2 function and operates in the same manner as a non-integrated IAT2. For additional information on the MAP portion of the TMAP, refer to the Thermal Manifold Absolute Pressure Sensor description and operation found later. Restraint System - SRS Lamp ON/DTC B1342 Set Air Bag Control Module: All Technical Service Bulletins Restraint System - SRS Lamp ON/DTC B1342 Set TSB 04-25-15 12/27/04 DIAGNOSTIC TROUBLE CODE (DTC) B1342 - RESTRAINT CONTROL MODULE (RCM) DIAGNOSTIC SERVICE TIP FORD: 2001-2004 Crown Victoria 2001-2003 Windstar 2004-2005 Freestar LINCOLN: 2001-2004 Town Car MERCURY: 2001-2004 Grand Marquis 2004-2005 Monterey This article supersedes TSB 04-13-6 to add a vehicle line and update the Service Procedure. ISSUE Some vehicles may exhibit the airbag warning indicator illuminated and DTC B1342 present in the restraint control module (RCM). The DTC can be set by an impact severity (crash) sensor, shorted airbag wiring or the RCM. ACTION Determine whether the vehicle is equipped with side airbags, or not. Follow the appropriate Service Procedure below to determine the cause. SERVICE PROCEDURE - VEHICLES WITH SIDE AIRBAGS NOTE SIDE IMPACT SENSORS ARE LOCATED IN THE B-PILLAR OR THE SEAT RISER PAN AREA (REFER TO THE ONLINE WIRING DIAGRAMS FOR LOCATION). FREESTAR/MONTEREY VEHICLES, EQUIPPED WITH SIDE AIR CURTAINS, WILL ALSO HAVE AN ADDITIONAL IMPACT SENSOR IN EACH C-PILLAR. 1. Begin by disconnecting the forward (front) impact severity (crash) sensor and attempting to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. b. If DTC B1342 is still present, reconnect the front impact severity sensor and continue by disconnecting each SIDE impact severity sensor, one at a time. Attempt to clear the B1342 DTC. (1) If DTC B1342 will clear after any side impact sensor is disconnected, and only DTC B2296 is still present, replace that impact sensor. Clear DTCs and return the vehicle to the customer. (2) If DTC B1342 is still present after disconnecting each side impact sensor and after attempting to clear the DTC, proceed to Step 2. 2. Check circuits to the front and side impact sensors for shorts to ground, verify power and ground circuits to the RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is still present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS-CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITH SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press Trigger. Page 6764 Page 9511 Tail Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 584 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Gasoline Fuel System Inertia Fuel Shutoff Switch: Description and Operation Gasoline Fuel System INERTIA FUEL SHUTOFF (IFS) SWITCH Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch (Figure 76) 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 a steel ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset before restarting the vehicle. Refer to the Owner Guide for the location of the IFS. Page 8997 16. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 17. Connect the passenger side safety canopy module electrical connector. 18. Install the D-pillar trim panel. 1 Position and install the D-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weatherstrip. 19. Position the attachments and install the screws. Page 627 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 170 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0152 refer to chart Page 6657 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 7725 striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 4. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the driver seat. 5. NOTE: - The manual seat track seat position sensor is shown, the power seat track position sensor is similar. - Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8933 Power and Ground Distribution Diagrams contain the diagrams that show 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 components are shown. These ground connection details are shown here in order to keep the individual set of diagrams as uncluttered as possible. Component and Connector Information Locations information that can be found at the vehicle level will help the user find where the various items depicted on the diagram can physically be found on the vehicle. Component Location Views show the components and their connecting wires as they can be found on the vehicle. "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. 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, tailpipe, catalytic converter and muffler. ^ Do not allow flame or sparks near the battery. Gases are always present in and around the battery cell. 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. Location Key For Connectors, Grounds, and Splices The first digit of every connector, ground, and splice references its location within the vehicle. NUMBER ............................................................................................................................................. ........................................................... LOCATION 100 .................................................................................................................. Engine compartment, Powertrain (including: axle/differential/transmission) 200 ................................................................................................................................................ Instrument Panel and Console, Steering Wheel assembly 300 .............................................................................................................................................. From instrument panel to rear seat, below door trim panel 400 ................................................................... ............................................................................................... Behind rear seats, to rear bumper; Truck bed 500 ...................................................................................................................................... ................................................................................. Driver door 600 .................................................. ...................................................................................................................................................... Passenger door, front 700 ................................................................................................................... ................................................................................ Passenger door, left rear 800 ............................. .............................................................................................................................................................. ...... Passenger door, right rear Page 5363 4. Remove the parts in the order indicated in the following illustration and table. 5. To install, reverse the removal procedure. 6. Fill the transmission with the specified quantity of the specified lubricant. Item 1: Front Axle Wheel Hub Retainer Removal Note 1. CAUTION: The front axle wheel hub retainer is a torque prevailing design nut. Do not reuse this nut. Remove the retainer and washer. ^ Insert a steel rod in the brake disc to prevent the halfshaft from turning while removing the retainer. Page 1538 Parking Assist Control Module: Service and Repair PARKING AID MODULE REMOVAL 1. Remove the RH quarter trim panel. NOTE: Rear parking aid module shown, front and rear parking aid module similar. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Locations View 151-5 Page 9552 Trailer Tow C439 (4-pin Connector) Trailer Tow Parking Lamp Relay C1199, Trailer Tow RH Turn Relay C1187, Trailer Tow LH Turn Relay C1188 Test W Page 8617 Page 853 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1293 Part 7 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 398 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1355 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 8423 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Page 143 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2842 Drive Belt: Component Tests and General Diagnostics Belt Tensioner The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by replacing the suspect drive belt with a known good O.E.M. drive belt and repeating the observation. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. NOTE: Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use. Replacement drive belts, other than O.E.M., may track differently/incorrectly. If a replacement drive belt tracks incorrectly, a new drive belt should be installed with an O.E.M. drive belt to avoid performance failure or loss of drive belt during cold operation. With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension, chirp, and squeal noises. If the above procedures do not correct the drive belt noise, try installing a drive belt with a known good O.E.M. drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as required. - Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck belt tracking. - Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking. Page 7435 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Page 3635 Trailer Tow Relay, Right Turn Page 6120 Note: The bussed electrical center is located in the engine compartment. Page 5998 Page 5495 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Brake Pressure Switch: All Technical Service Bulletins ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 8931 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 470 P0400 - P0404: Testing and Inspection P0402 For diagnosis of code P0402 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and A/T - Erratic Fluid Level Readings/Filler Tube Leaks Case: Customer Interest A/T - Erratic Fluid Level Readings/Filler Tube Leaks TSB 06-18-13 09/18/06 ERRATIC FLUID LEVEL READING ON TRANSAXLE DIPSTICK - LEAKS - 4F50N, AX4N, AX4S FORD: 2000-2007 Taurus 2000-2007 Windstar 2004-2007 Freestar MERCURY: 2000-2005 Sable 2004-2007 Monterey This article supersedes TSB 05-14-5 to update the Service Procedure and vehicle model years. ISSUE Some 2000-2007 Taurus, 2000-2005 Sable, 2000-2003 Windstar, and 2004-2007 Freestar/Monterey vehicles, equipped with a 4F50N, AX4N, or AX4S transaxle, may exhibit an erratic fluid level reading on the transaxle dipstick and possible leaks around the filler tube and grommet. The condition may be due to a restricted transaxle vent. ACTION Repair the transaxle vent restriction by replacing the transaxle vent with a 90° vent stem, small hose clamp, two (2) tie raps, and 24" (61 cm) of 5/16" (8 mm) vacuum hose. The 5/16" (8 mm) vacuum hose will be routed from the 90° vent on the transaxle back to the cowl area, next to the brake master cylinder and tie rapped in place with the end of the hose facing down. Refer to the following Service Procedures. NOTE ON WINDSTAR, FREESTAR AND MONTEREY SEAL THE COWL PANEL GRILLE (COWL TO VENT PANEL) AREA, SEE TSB 06-14-10. NOTE LEAKS MAY BE MISDIAGNOSED AS COMING FROM THE PAN GASKET. ALWAYS FOLLOW WORKSHOP MANUAL, SECTION 307-01 TO LOCATE THE SOURCE OF A LEAK, AND LEAK CHECK WITH BLACK LIGHT AND DYE. SERVICE PROCEDURE 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Disconnect the crankcase vent tube(s) from the air cleaner outlet pipe. 3. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body. 4. Release the air cleaner housing clamp(s). 5. Separate the air cleaner cover from the air cleaner tray. 6. Windstar, Freestar and Monterey only: Remove cowl panel grille by following the procedure in TSB 06-14-10. 7. Disconnect the shift cable if located over the top of the vent. 8. Remove the vent, pull straight up on the vent with locking pliers, or carefully pry the vent from the transaxle case. 9. Install the replacement 90° vent stem. Page 4442 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 2869 Heater Hose: Vehicle Damage Warnings CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. Locations Page 4491 Intake Air Temperature Sensor: Description and Operation Thermal Manifold Absolute Pressure Sensor THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 1993 Page 1006 P1245 - P1249: Testing and Inspection P1246 For diagnosis of P1246 refer to the system experiencing the problem. Computers and Control Systems P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5163 Service Procedure, Includes Time To Check And Fill Transmission Fluid (Do Not Use With 1 7526A, 17566A, 17508A, 17603A, 9600A, 9601A) 061813B 2004-2007 1.3 Hrs. Freestar/Monterey, 2000-2003 Windstar: Replace Transaxle Vent Following Service Procedure, Includes Time To Remove And Reseal The Cowl Panel Grille, Check And Fill Transmission Fluid (Do Not Use With 17526A, 17566A, 17508A, 17603A, 9600A, 9601A, 061410A) DEALER CODING CONDITION BASIC PART NO. CODE 7L282 41 Disclaimer P0325 P0325 - P0329: Testing and Inspection P0325 For diagnosis of code P0325 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1482 P2195 - P2199: Testing and Inspection P2198 OBD II - Base Gasoline For diagnosis of code P2198 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P2198 refer to chart Page 266 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 9521 92-2 Page 2809 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Diagrams Power Trunk / Liftgate Control Module: Diagrams Page 1130 P1405 - P1409: Testing and Inspection P1408 For diagnosis of code P1408 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 7463 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 8667 Fuse and Relay Information Fuse/Locations and Relay/Locations contains a view of the fuse/relay box in which all fuses and relays are identified. Power Distribution Power and Ground Distribution Diagrams show the current feed circuit. 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 Page 7260 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Page 3713 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 4900 key-off time to get the BARO to update, prior to turning the key to the start/run position. 2. BARO may also be adjusted based on MAF and MAP sensors readings under certain driving conditions, as long as no DTCs or faults are present. Typical conditions are stabilized engine temperatures and high to moderate throttle openings. 3. BARO will adjust to a default value if faults are presents or the keep alive memory (KAM) is cleared. A low battery voltage or a KAM reset performed by a scan tool will clear KAM. The default value depends on how the vehicle application was calibrated. (example the BARO value may read 27 in-Hg (150Hz) when the KAM was cleared, but the actually barometric pressure due to geographical region may be different.) Use the following verification method to check BARO. NOTE TO VERIFY BARO IN VEHICLES EQUIPPED WITH ESM'S YOU WILL NEED A SCAN TOOL AND THE BAROMETRIC PRESSURE/MAP SENSOR REFERENCE CHART. DIAGNOSTICS 1. If DTCs other than P2106, P0106, P0107, P0401 P0402 are present, repair these first. If the KAM is reset during the repairs then proceed to Step 3. 2. Do not reset KAM. 3. Make sure the key is off for at least 1 minute. 4. Connect the scan tool. 5. Turn key on, do not start the engine. 6. Setup scan tool to read BARO PID and MAP_V (MAP sensor voltage). 7. Verify if BARO PID and MAP voltage matches barometric pressure for appropriate geographical location using the barometric pressure/MAP sensor reference chart. (Example, if the MAP_V reads approximately 4.20 V then the BARO PID should read about 156Hz which would correspond to a region where the barometric pressure is approximately 29 in-HG. Verify with local weather reports and altitude readings.) a. If the key-on BARO is not appropriate for the geographical region verify the MAP sensor is puffing out the correct voltage by comparing MAP_V PID and the actual voltage at pin-3 of the ESM (use pin-6 for the ground reference). If there is a discrepancy greater than 0.2 volts then perform the following checks. (1) Check ESM wires and connections for shorts and opens. (2) Check for internal ESM short. Check resistance between pin-2 (VREF) and pin-6 (signal return) on the ESM with ESM harness disconnected. If resistance is less then 2000 OHMS then replace ESM and retest. WARRANTY STATUS: Information Only Page 427 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6787 Item 4: Coil Spring Assembly Note 1. If installing a new spring, make sure the part number is correct. Refer to the vehicle certification (VC) label for the correct spring code. Page 6555 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Service and Repair Rear Door Exterior Handle: Service and Repair SLIDING DOOR HANDLES Heavy Duty Riveter SPECIAL TOOL(S) REMOVAL NOTE: Right side shown, left side similar. 1. Remove the sliding door trim panel. Page 6035 Battery: Diagrams Locations View 151-15 Page 5065 100303B 2004-2005 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) 100303C 2006-2007 Freestar, 1.0 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) 100303D 2006-2007 Freestar, 1.2 Hrs. Monterey: Check DTCs, Inspect PCM For Water Intrusion, Replace And Modify The New PCM Following Service Procedure. Includes Time To Program PATS Keys (Do Not Use With Any Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 04 Disclaimer Page 9439 Gasoline Fuel System Fuel Pressure Test Port: Description and Operation Gasoline Fuel System PRESSURE TEST POINT There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE TEST KIT #134-R0087 OR EQUIVALENT. Trailer Tow Relay, Right Turn Page 8420 Deactivation Procedure WARNING: If the supplemental restraint system (SRS) is being serviced, the system must be deactivated and restraint system diagnostic tools must be installed. Refer to Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS). The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Never probe the connectors on a safety canopy module. Doing so can result in safety canopy module deployment. NOTE: Diagnostics or repairs are not to be carried out on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. WARNING: To avoid accidental deployment and possible personal injury, the RCM backup power supply must be depleted before repairing or replacing any front or side air bag (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. Open the steering wheel access door. Through the steering wheel access door opening, release the tab and disconnect the driver air bag module electrical connector. 3. Attach restraint system diagnostic tool 418-F403 to the clockspring side of the driver air bag module electrical connector. 4. Lower the glove compartment to access the passenger air bag module electrical connector. 5. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. 6. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger air bag module electrical connector. 7. Remove the RH D-pillar trim panel. 8. Disconnect the passenger side safety canopy module electrical connector. Locations Blower Motor Switch: Locations View 151-8 Page 5359 10. Using special tool 205-343 (T95T-3514-A), secure the 2 inner bellows clamps. 11. Reinstall the steering gear per Section 211-00 of the Workshop Manual. 12. Perform a front wheel alignment. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050908A 2004-2005 2.5 Hrs. Freestar/Monterey Replace One Halfshaft, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) 050908B 2004-2005 2.8 Hrs. Freestar/Monterey Replace Both Halfshafts, Install The Restrictors On The Rack Between The Inner Tie-Rod And The Steering Gear Housing, Then Check And Correct Front Wheel Alignment (Do Not Use With 3329AR, 3329AL, 3329AT, 3504A) DEALER CODING CONDITION BASIC PART NO. CODE 3B436 01 Disclaimer Page 3810 Disclaimer Page 7752 Description and Operation Manifold Pressure/Vacuum Sensor: Description and Operation THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR Thermal Manifold Absolute Pressure (TMAP) Sensor The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 48) consists of a manifold absolute pressure (MAP) sensor and an integrated thermistor. The MAP portion of the sensor uses a piezo-resistive silicon sensing element to provide a voltage proportional to the absolute pressure in the intake manifold. The thermistor portion of the sensor operates in the same manner as an intake air temperature (IAT) sensor. For additional information on how the IAT sensor operates, refer to the Intake Air Temperature Sensor description and operation. For the 2.3L Ranger and 2.3L PZEV Focus, the TMAP sensor is part of the Exhaust Gas Recirculation (EGR) system. The PCM uses information from the MAP portion of the TMAP sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor and crankshaft position (CKP) sensor to determine how much exhaust gas is introduced into the intake manifold. The thermistor portion of the TMAP sensor is currently not being used on this application. For the 4.6L SC Mustang, the PCM uses manifold absolute pressure information from the MAP portion of the TMAP sensor along with other sensor inputs to determine the proper amount of fuel needed for combustion under varying engine load conditions. The thermistor portion of the TMAP sensor is used as a second IAT sensor. This second IAT sensor, located after the supercharger, provides manifold air temperature information to the PCM. Page 7538 Page 7601 20. Position the safety belt guide and install the bolt. 21. Install the safety belt guide cover. All vehicles 22. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. 23. Through the glove compartment opening, connect the passenger air bag module electrical connector. 24. Close the glove compartment. Page 368 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 868 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Specifications Exhaust Manifold: Specifications Torque Sequence RH Torque Sequence LH Exhaust manifold bolts ........................................................................................................................ ...................................................... 25 Nm (18 ft. lbs) Description and Operation Air Diverter Valve: Description and Operation AIR DIVERTER VALVE Air Injection Diverter (AIR Diverter) Valve The secondary air injection diverter (AIR diverter) valve (Figure 114) is used with the electric AIR pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter valve, the integral check valve disk is held on the seat and stops air from being drawn into the exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System. Page 585 P0535 - P0539: Testing and Inspection P0538 For diagnosis of code P0538 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 3368 2. NOTE: Front seal shown, rear seal similar. Install the lower intake manifold front and rear seals. 1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal mounting points as shown. 2. Install the lower intake manifold front and rear seals. 3. Install the intake manifold gaskets. Page 1409 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6048 Battery: Service and Repair Battery Disconnect BATTERY DISCONNECT WARNING: - Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery, always shield your face and protect your eyes. Always provide ventilation. Failure to follow these instructions may result in personal injury. - To avoid accidental deployment and possible injury, the backup power supply must be depleted before repairing or installing any front or side air bag supplemental restraint system (SRS) components and before repairing, installing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect any auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. - When lifting a battery, excessive pressure on the end walls could cause acid to spew through the vent caps, resulting in personal injury. Lift with a battery carrier or with your hands on opposite corners. Failure to follow these instructions may result in personal injury. - Keep out of the reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Also, shield your eyes when working near the battery to protect against possible splashing of the acid solution. In case of acid contact with the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Failure to follow these instructions may result in personal injury. NOTE: When the battery is 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 its strategy. 1. Disconnect the parts in the order indicated in the illustration and table. 2. To reconnect, reverse the disconnect procedure. Page 523 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Evaporative Emissions System DTC Index P0442 - P1450 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete Evaporative Emissions diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2463 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Page 5957 View 151-13 Page 8124 Test W12 Normal Operation The trailer tow relays are supplied power from the BEC. Ground for the trailer tow parking lamp relay is provided through circuit 576 (DG). Ground for the trailer tow LH turn lamp relay is provided through circuit 374 (DB/WH). Ground for the trailer tow RH turn lamp relay is provided through circuit 378 (BN/YE). Ground for the trailer tow relay coils is controlled by the SJB. When the trailer tow parking lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 962 (BN/WH). When the trailer tow LH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 52 (YE). When the trailer tow RH turn lamp relay is energized, voltage is routed from the BEC to the trailer tow connector through circuit 64 (DG). Ground is supplied to the trailer through circuit 206 (WH). Possible Causes - circuit 52 (YE) open - circuit 64 (DG) open - circuit 206 (WH) open - circuit 374 (DB/WH) open or short to power - circuit 378 (BN/YE) open or short to power - circuit 576 (DG) open or short to power - circuit 962 (BN/WH) open - trailer tow relay - trailer - BEC - SJB Test X PINPOINT TEST X: THE TRAILER LAMPS ARE ON CONTINUOUSLY Test X1-X2 Page 3003 Special Tool(s) Page 1053 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 4218 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 4948 Symptom Chart Page 1855 Specifications Axle Nut: Specifications Note: Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut Axle nut ................................................................................................................................................ ................................................... 130 Nm (96 ft.lbs.) Page 8999 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. System Diagnosis P0655 - P0659: Testing and Inspection For diagnosis of code P0657 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 9635 Power Window Switch: Testing and Inspection Power Window Switch, RH Side Front Page 5713 Part 3 Of 3 3. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: To remove individual parts, only carry out the listed steps: (Continued) 4. To install, reverse the removal procedure. Item 1: Redundant Self Locking Pin Cover Removal Note Trailer Tow Relay, Parking Lamp P1516 P1515 - P1519: Testing and Inspection P1516 For diagnosis of code P1516 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4216 11. Place two (2) of the cut pieces of the PVC sofi foam adhesive stripes on the metal body surface over the transaxle area. The two ends need to touch, do not allow any gap between the two ends. (Figure 8) 12. Place the other two cut pieces of the PVC soft foam adhesive stripes on the metal body surface over the PCM area. The two ends need to touch, do not allow any gap between the two ends. (Figure 9) 13. Check that the three (3) rubber plugs and five (5) gray plastic clips are fully seated. Add Clear Silicone Rubber around the three (3) rubber plugs and the five (5) gray plastic clips. (Figure 10) Page 9455 Description and Operation Knock Sensor: Description and Operation KNOCK SENSOR Two Types Of Knock Sensor (KS) The knock sensor (KS) (Figure 41) 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. Page 3966 Page 6748 Item 11: Wheel Stud Installation Note 1. Using a suitable press, install a new wheel stud. Item 10: Lower Arm (LH/RH) Installation Note 1. CAUTION: The lower control arm attachment-to-subframe bolts contain thread adhesive. Do not partially remove bolts. When removing or installing bolts, do so with one continuous sequence to prevent the adhesive from setting. Do not use air tools to tighten the lower arm nuts and bolts. Item 3: Wheel Hub and Bearing Assembly Installation Note 1. Position the dust shield over the hub and bearing assembly, then fit the hub and bearing into the knuckle and seat it fully before installing the retaining bolts. Item 1: Axle Shaft Nut Installation Note 1. Apply a small patch of threadlock to the last five axle shaft Joint threads before installing the nut. Page 5624 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Locations View 151-11 Electrical - ABS/TCS/Park Brake Lamps Flickering Traction Control Indicator Lamp: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). General Procedures Heater Hose: Service and Repair General Procedures HEATER HOSE COUPLING Special Tool(s) SPECIAL TOOL(S) DISCONNECT CAUTION: Do not attempt to install a new bushing, spacer or O-rings in the heater hose coupling; damage to the heater hose coupling can result. If the heater hose coupling is the cause of a coolant leak, the affected heater hose must be replaced as an assembly. 1. WARNING: The engine must be off, fully cool and the cooling system fully depressurized before attempting to disconnect any heater water hoses. Failure to comply with this warning can result in serious injury or burns from hot liquid escaping out of the engine cooling system. Depressurize the engine cooling system. 2. Push the heater hose toward the tube to fully expose the locking tabs. 3. NOTE: - When compressing the white coupling retainer with the special tool, the special tool must be perpendicular to and on the highest point of the coupling. - If the heater hose coupling is accessible, the retainer tabs can be compressed by hand to disconnect the heater hose. Push the special tool over the coupling retainer windows to compress the retainer locking tabs. System Diagnosis P2000 - P2004: Testing and Inspection For diagnosis of code P2004 refer to chart P1641-P2106 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 1320 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: Page 5640 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 4737 View 151-5 Specifications Vacuum Brake Booster: Specifications Brake booster nuts .............................................................................................................................. ...................................................... 25 Nm (18 ft. lbs.) Page 6460 Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 4214 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Page 6361 Page 9211 Test F1-F3 Page 6359 Page 9574 Page 1561 Power Sliding Door Module: Testing and Inspection POWER SLIDING DOOR MODULE SELF-TEST WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. The PSD self-test will attempt to power open and close the PSD. As the PSD is opened and closed, the PSD monitors the system for correct inputs. Upon completing the self-test, DTCs will be logged for any incorrect operations. The PSD also checks the following inputs during a self-test: - overhead console on/off switch circuit - overhead console open/close switch/RKE circuits - B-pillar switch circuit - PARK (enable) circuit from the SJB - vehicle speed circuit from SJB - fuel filler door circuit (left PSD only) The PSD has the ability to reverse the PSD operation if certain conditions exist. This is a normal function of the system, however some electrical concerns may cause the same symptom. If the PSD reverses during operation or during the self-test, always check for an obstruction or misalignment first. If no obstruction or misalignment is found, make sure to complete all DTC and symptom diagnostics. Initialization Procedure If the PSD loses the logic battery supply for any reason, such as battery disconnect, module disconnect or if left open for more than 6 hours, the PSD will lose the PSD position stored in memory. Disconnecting the battery will cause both PSDs to lose PSD position. Disconnecting the PSD connector will only cause the specific module to lose its memory. If only one PSD module is affected, the initialization procedure only needs to be carried out for the specific module. The PSD normal operation will not be restored until the PSD position is once again stored into memory. The initialization procedure is the learning process the PSD uses to restore the PSD position in memory. The PSD monitors the position sensor data received during the initial power open-and-close operation to learn the positions. Refer to Power Sliding Door Initialization. Page 5601 Steering Angle Sensor: Service and Repair Steering Wheel Rotation Sensor NOTE: When installing a new steering wheel rotation sensor, the ABS module must be configured (using vehicle as-built data) and calibrated. Follow the diagnostic tool directions for the configuration procedures. 1. Remove the parts in the order indicated in the following illustration and table. Locations View 151-5 Page 9187 Symbols Part 2 Service Precautions Condenser HVAC: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Liftgate Ajar Switch Page 8770 Page 5656 View 151-4 Page 9519 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 8657 Part 2 3. Disassemble the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 7: Backrest-to-Cushion Nuts Disassembly Note 1. Remove the four (two shown) backrest-to-cushion nuts. 2. Backrest-to-cushion removal. 1 Release the hook-and-loop fastener and remove fabric flap. 2 Release the center J-clips. 3 Pull the center material down and route the material behind the tether anchor bar and remove the seat backrest. Item 10: Cushion Trim Cover Disassembly Note Page 7630 and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 6. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 7. Connect the battery ground cable. 8. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 9. Check the active restraint system for correct operation. Item 15: Safety Belt Buckle Pretensioner Assembly Installation Note 1. The anti-rotation tab must be correctly aligned for correct installation. - After installing the safety belt buckle pretensioner assembly, reconnect the safety belt buckle switch connector. Item 13: Seat Side Trim Panel Installation Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. After completing the installation of the passenger seat side trim panel and seat, the OCS system must be rezeroed to ensure system integrity. Item 11: Seat Assembly Installation Note 1. Install the seat. When installing the seat, make sure the wiring harness is routed correctly and is not in a position to be pinched. Item 8: Upper B-pillar Trim Panel Installation Note 1. Make sure when installing the upper B-pillar trim panel, the weatherstrip around the door openings is in the correct position. Item 4: Height Adjuster Button Cover Installation Note 1. To install the height adjuster button cover, squeeze the buttons and place the bottom of the cover in first. Item 3: Lower B-Pillar Trim Panel Installation Note 1. Make sure when installing the lower B-pillar trim panel, the weatherstrip around the door openings is in the correct position. Bench Seat Page 8480 NOTE: All of the doors must be closed during the perimeter lighting programming procedure. 1. Turn the key to ON. 2. Press the UNLOCK button 3 times. 3. Turn the key to OFF. 4. Press the UNLOCK button 3 times. 5. Turn the key to ON. 6. Press the UNLOCK button, then press the UNLOCK button again. The horn will chirp once if the perimeter lighting feature was just deactivated or it will chirp twice (1 short chirp and 1 long chirp) if the perimeter lighting feature was just activated. 7. Turn the key to OFF. The horn will chirp to confirm the procedure is complete. Unlock Inhibit Programming NOTE: All of the doors must be closed during the unlock inhibit programming procedure. 1. Turn the key to ON. 2. Press the UNLOCK button 3 times. 3. Turn the key to OFF. 4. Press the UNLOCK button 3 times. 5. Turn the key to ON. 6. Press the LOCK button, then press the LOCK button again. The horn will chirp once if the unlock inhibit feature was just deactivated or it will chirp twice (1 short chirp and 1 long chirp) if the unlock inhibit feature was just activated. 7. Turn the key to OFF. The horn will chirp to confirm the procedure is complete. Page 2237 Page 5876 Part 1 Of 2 Page 2752 Alignment: Description and Operation Suspension System Camber, caster and toe are adjustable for the front suspension system. The front camber and caster are adjusted by resetting the alignment plates on the shock towers. The front toe is adjusted at the front knuckle tie rods. 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. Part 1 Of 2 Part 2 Of 2 Caster P1275 P1275 - P1279: Testing and Inspection P1275 OBD II - Base Gasoline For diagnosis of code P1275 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 5422 Material Material 1. With the vehicle in neutral, position it on a hoist. 2. Remove the transaxle. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: Item 3: Crankshaft Rear Seal Removal Note 1. Using the special tools, remove the crankshaft rear seal. Page 8095 Diagram 3-3 Current Flow (1) Each set of diagrams 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. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the diagrams. 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 the diagram, all switches, sensors and relays are shown "at rest" (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the diagram where the splice appears in full. Component Referencing (4) Each component on a diagram has a reference to the component location view for that component (i.e. 151-1, 151-10, etc.). These view references are located to the right of each component shown in a diagram. The views themselves can be found at Vehicle Locations. Component Names, Notes and Base Part Numbers (5) Component names are placed on the right hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The base part number for a component is listed in parentheses next to or under a component. Internal Name and Function ID Numbers (6) Some components on each diagram have internal symbols with an identification number located to the right. You can identify the internal symbol or function by finding the corresponding number under the component name. Page 8121 Test W6-W8 Page 2451 Throttle Position Sensor: Description and Operation THROTTLE POSITION SENSOR The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is monitored by the OBD system for component integrity, system functionality, and faults that can cause emissions levels to exceed standards set in government regulations. For additional information on the TP sensor, refer to Electronic EC System Hardware-PCM Inputs. Page 7557 Air Bag Control Module: Service and Repair General Procedures Missing Weld Nut WELD NUT REPAIR - MISSING WELD NUT CAUTION: Installing a J-nut in place of a weld nut is not a recommended repair. NOTE: C-pillar repair shown, others similar. 1. Remove the component from where the weld nut is to be repaired. 2. Drill three equally spaced 5/64 in (1.75 mm) holes in close proximity to where the weld nut face will be plug welded back to the sheet metal. 3. Obtain the appropriate 6 mm (0.24 in) or 8 mm (0.32 in) weld nut. 4. Obtain the appropriate 6 mm (0.24 in) by 1.0 or 8 mm (0.32 in) by 1.25 grounding screw (self-tapping). 5. Set up for the positioning of the weld nut. 1 Route a sufficient length of wire through the weld nut clearance hole and back out an adjacent access hole. 2 Position a weld nut, shoulder end up, onto the wire. 3 Position a flat washer onto the wire and secure it so it cannot be pulled off. 6. Plug weld the weld nut into position. 1 Pull the welding wire back through the clearance hole, allowing the weld nut and flat washer to follow the welding wire through and stop against the sheet metal. 2 Make sure the weld nut shoulder is aligned through the clearance hole in the sheet metal. 3 With the weld nut firmly held in position, plug weld the weld nut at the three holes drilled previously. Bussed Electrical Center (BEC) Relay Box: Diagrams Bussed Electrical Center (BEC) Page 7198 Page 173 P0150 - P0154: Testing and Inspection P0153 For diagnosis of code P0153 refer to chart P0148-P0191 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3472 Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE Special Tool(s) SPECIAL TOOL(S) WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. 1. NOTE: The fuel pump relay is located in the engine compartment fuse box location K4/C-1051. Remove the fuel pump relay. 2. Start the engine and allow it to idle until it stalls. 3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel injection supply manifold pressure has been released. 4. Turn the ignition switch to the OFF position. 5. When fuel system service is complete, install the fuel pump relay. 6. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait three seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. NOTE: If fuel system pressure testing is necessary, carry out the following steps. 8. Release the fuel tube clip at the fuel supply manifold. Page 9321 Symbols Part 3 Page 758 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a Cabin Air Filter Locations View 151-6 Page 357 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2152 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Removal and Installation 1. Raise and support the vehicle. NOTE: Clean the area around the sensor hole prior to removal. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 3: Wheel Speed Sensor Installation Note 1. Lube the O-ring before installing a new wheel speed sensor. Page 6247 Page 7103 Special Tool(s) Page 6569 Part 2 Of 2 Rear Ride Height Measurement Part 1 Of 2 Part 2 Of 2 Wheel Track Page 9477 Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Service and Repair Shift Interlock Solenoid: Service and Repair Brake Shift Interlock Actuator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Page 3964 Disclaimer Page 5593 INSTALL THE NEW SWA SENSOR WITH CARE TO ENSURE THE OUTSIDE HOUSING IS NOT SCRATCHED. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071011A 2004-2007 0.6 Hr. Freestar/Monterey: Check DTCs, Replace The SWA Sensor And Tone Ring, Includes Time To Configure The Anti-Lock Brake Module. (Do Not Use With 12651D, 12651D4) DEALER CODING CONDITION BASIC PART NO. CODE 3F818 42 Disclaimer Page 3681 1. Disconnect the EGR tube. ^ Loosen the nut. ^ Separate the EGR tube from the manifold. Item 3: Exhaust Manifold Nut Installation Note Page 6672 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Page 7115 4. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. 2. Lubricate the refrigerant system with the correct amount of clean PAG oil. 3. Evacuate, leak test and charge the refrigerant system. Page 2888 6. Remove the line brackets and the front auxiliary evaporator outlet and inlet lines. 7. Disconnect the fittings at the rear tube-in-tube fitting. - Discard the O-ring seals. 8. Remove the bolts and the line brackets. 9. Remove the auxiliary tube-in-tube assembly. INSTALLATION 1. To install, reverse the removal procedure. - Install new O-ring seals lubricated in clean mineral oil. - Lubricate the refrigerant system with the correct amount of clean PAG oil. 2. Evacuate, leak test and charge the refrigerant system. Page 8567 Page 22 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Locations Locations View 151-5 Page 2671 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 2375 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. P0750 P0750 - P0754: Testing and Inspection P0750 Torqshift For diagnosis of code P0750 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6487 Page 2682 View 151-9 Page 2622 With the restraint system diagnostic tools still installed at the remaining deployable devices, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 7. Disconnect the battery ground cable and wait at least one minute. 8. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Reactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. 9. Connect the battery ground cable. 10. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. Item 1: Seat Cushion Pan Installation Note 1. Bend the retaining ear back on the pressure sensor component bracket. Item 2: Bladder, Occupant Classification Sensor (OCS) Installation Note 1. CAUTION: - Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in Page 7419 Diagrams Page 8714 View 151-15 Page 2563 View 151-14 Page 2214 Service and Repair Radiator: Service and Repair REMOVAL AND INSTALLATION Radiator, Cooling Fan and Shroud Material Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the transmission fluid cooler. Part 1 Of 2 Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation FUEL CAP OFF INDICATOR LAMP The Fuel Cap Off Indicator Lamp (FCIL) is an output signal that is controlled by the PCM and will illuminate when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed properly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. NOTE: The Escape, Freestar/Monterey, Mustang, Thunderbird, Town Car, Lincoln LS6/LS8, Expedition and Navigator do not have a dedicated (separate) output wire from the PCM to the instrument cluster. The PCM commands the FCIL on and off through the BUS +/- circuits (SCP). Page 7433 (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Vehicles equipped with second row bucket seats shown, vehicles equipped with a second row bench seat are similar. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Deactivate the supplemental restraint system (SRS). Refer to Air Bag(s) Arming and Disarming. Page 7438 Special Tool(s) Page 735 P0745 - P0749: Testing and Inspection Torqshift For diagnosis of code P0748 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Service and Repair Shifter A/T: Service and Repair Transmission Selector Lever 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. Item 1: Ignition Switch Lock Cylinder Removal Note 1. Remove the ignition switch lock cylinder. 1 Rotate the ignition switch to the run position. 2 Press the lock cylinder release pin and remove the ignition switch lock cylinder. Page 4807 Auxiliary Relay Box Page 8650 Part 2 3. Disassemble the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Recliner Handle Clip Disassembly Note Page 1848 Locations View 151-13 Page 9258 Page 8148 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 436 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 2450 Page 1490 P2255 - P2259: Testing and Inspection P2258 For diagnosis of code P2258 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3973 Page 693 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5872 Brake Master Cylinder: Diagrams Part 1 Of 2 Page 8387 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. Service and Repair Flywheel: Service and Repair Flexplate or Flywheel and Crankshaft Rear Seal Special Tools And Equipment Special Tools And Equipment Special Tool(s) Page 7813 Part 2 4. CAUTION: - While positioning the seat cushion pan and occupant classification sensor (OCS) assembly, be careful not to damage any of the components. Failure to do so can result in component failure. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Remove the parts in the order indicated in the illustrations and tables. Item 1: Recliner Handle Cover Removal Note Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Locations View 151-18 Page 230 Inspection Page 8875 View 151-13 Specifications Fuel: Specifications Fuel Capacity ....................................................................................................................................... .......................................................... 26 gal (98.4 L) P0196 P0195 - P0199: Testing and Inspection P0196 For diagnosis of code P0196 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 1122 Inspection Page 478 Inspection Page 9404 - headlamp switch - BEC - SJB Test P PINPOINT TEST P: THE PARKING, REAR OR LICENSE LAMPS ARE ON CONTINUOUSLY Test P1-P3 Page 8377 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 2737 Windshield Washer Switch: Diagrams A/C - Compressor Leaking/Inoperative Compressor Shaft Seal: All Technical Service Bulletins A/C - Compressor Leaking/Inoperative TSB 06-4-9 03/06/06 A/C COMPRESSOR NOT OPERATIONAL / LOW FREON-SHAFT SEAL LEAKS FORD: 2003 Escort 2003-2006 Focus, Mustang, Taurus 2003 Explorer Sport, Windstar 2003-2005 Excursion, Explorer Sport Trac 2003-2006 Escape, F-150, F-Super Duty, Ranger 2004-2006 Freestar 2006 Low Cab Forward LINCOLN: 2002 Blackwood 2006 Mark LT MERCURY: 2003-2005 Sable 2004-2006 Monterey 2005-2006 Mariner ISSUE Some 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal. ACTION Replace the A/C compressor shaft seal following the Service Procedure. SERVICE PROCEDURE If the shaft seal on the front of the A/C compressor is leaking, replace the shaft seal (F1VY-19D665-A) and not the compressor assembly. Replacing the shaft seal should correct the leaking condition. When replacing the seal, follow the procedure outlined in Workshop Manual, Section 412-03. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME MT060409 Use Standard Labor Actual Operation For Compressor Time Removal And Installation If Available, And Claim Additional Labor Required As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 19D665 42 Page 2931 ^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund claims that include other non-covered repairs or those judged by Ford to be excessive will not be accepted for reimbursement. ^ This safety recall must still be performed even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall. ^ Refund Claiming Information (Submit on separate repair line.) - Program Code: 03S09 - Misc. Expense: ADMIN - Misc. Expense: REFUND - Misc. Expense: 0.2 Hr. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ Refunds must be claimed on a repair line that is separate from the FSA's repair line. Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS / ORDERING INFORMATION There are no parts required for this recall. Attachment III - Technical Information OVERVIEW Page 842 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8011 Page 2268 Ambient Light Sensor: Service and Repair LIGHT SENSOR REMOVAL 1. Remove the LH and RH windshield side garnish mouldings. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 2601 Seat Belt Tension Sensor: Description and Operation Air Bag and Safety Belt Pretensioner SRS SAFETY BELT TENSION SENSOR The safety belt tension sensor: is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a three-wire Hall-effect sensor that is part of the front passenger safety belt and retractor assembly. The safety belt tension sensor is used by the OCS system to identify the presence of a child safety seat on the front outboard passenger seat. The safety belt tension sensor senses the tension on the safety belt assembly then provides an output to the OCS system electronic control unit (ECU), indicating that the safety belt assembly is cinched. After sensing the weight applied to the seat by the occupant and using the safety belt tension sensor input, the OCS system determines how the occupant should be classified and communicates this information to the restraints control module (RCM). If the occupant is classified to be a child, the RCM will then automatically deactivate the passenger air bag module and passenger safety belt pretensioner. Page 15 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3712 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 5896 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 3998 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Synchronizer Alignment Gauge SPECIAL TOOL(S) REMOVAL 1. Disconnect the battery ground cable. 2. If removing the camshaft synchronizer, drain the cooling system. 3. CAUTION: Do not turn the crankshaft or the camshaft after the No. 1 cylinder is at top dead center (TDC) of the compression stroke or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at top dead center (TDC) of the compression stroke. Page 7005 Illustration 1 Of 2 Page 2819 b. If evidence of water is not found, proceed to Step 4 with the vehicle's original PCM. 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4" (5 mm) hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft(R) Metal Surface Prep or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. Page 2621 system. NOTE: Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. Install the parts in the order indicated in the illustrations and tables. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. NOTE: Make sure the battery ground cable is still disconnected before proceeding with the installation portion of this procedure. Install the passenger seat into the vehicle. Do not reactivate or prove out the supplemental restraint system at this time. 3. Connect the battery ground cable. 4. CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing the OCS system: Make sure the OCS system components are connected and no faults are present. - Make sure the OCS system is not at a temperature below 0°C (32°F) or above 45°C (113°F) when initiating the rezeroing process. If the vehicle has been exposed to extreme cold or hot temperatures, the vehicle must be exposed and kept at a temperature within the limits, 0°C to 45°C (32°F to 113°F) for a minimum of 30 minutes. - Make sure nothing is present on the passenger seat before rezeroing and nothing is placed on the seat during the rezeroing process. - Make sure a minimum eight second time period has passed after cycling the ignition switch ON before the rezeroing process. NOTE: For best results in rezeroing, the OCS system should be at or near room temperature, 10°C to 29°C (50°F to 85°F). - When using a New Generation STAR (NGS) Tester you must use the appropriate memory card with the latest update to carry out this function. To rezero the OCS system: select "SERVICE BAY FUNCTIONS" - select "RCM" - select "SYSTEM RESET" - select the vehicle from the menu - view the on-screen information, then press "TRIGGER" The NGS screen will then display "OCS RESET: REZERO." Press "DONE" (button 8) to rezero the OCS system. The NGS will return to the vehicle menu once rezeroing of the OCS system is complete. NOTE: To rezero the OCS system using the Worldwide Diagnostic System (WDS): select the "Toolbox" icon - select "Body" from the menu - select "Restraints" from the menu - select "Seat Weight Sensor ReZero" After selecting "Seat Weight Sensor ReZero", follow the on-screen prompts to carry out rezeroing of the OCS system. NOTE: If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Rezero the occupant classification sensor. With the front passenger seat empty, use a scan tool to trigger the active command and rezero the occupant classification sensor. 5. NOTE: The ignition switch must be cycled after rezeroing the OCS system. Cycle the ignition switch from ON to OFF. 6. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. Page 7514 DTCs that use fault PIDs do not identify the specific concern. The DTC identifies the component(s) or type of component(s) in which the concern exists. The next level, fault PIDs, identifies the specific device and fault condition. Fault PIDs are available for both on-demand (active) and continuous memory (historic or intermittent) DTCs. A scan tool must be used to view the DTCs and their fault PIDs. The table lists those DTCs that are supported by associated fault PIDs. (Figures 1-5) VIEWING FAULT PIDS USING SCAN TOOLS WSM Direction to FLAG DTC/View Fault PIDs The information in viewing fault PIDs in the WSM has evolved over the years as the scan tools have transitioned. Examples of how the WSM may direct you to view fault PIDs are: ^ FLAG DTC XXXXX/Record All Flagged Faults (2001-2006 WS Ms) Page 2629 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Page 8641 1. Release the recliner handle cover tab and remove the handle. 2. Remove the side shield screw from behind the recliner handle. Item 10: Seat Side Air Bag Connector Disassembly Note 1. Disconnect and detach the seat side air bag connector and route through the seat cushion frame for backrest removal, noting the route for installation. 2. Detach and disconnect the backrest TED electrical connector and disconnect the backrest climate controlled seat duct from the climate controlled blower for backrest removal. 3. If equipped, disconnect the three memory seat motor position sensors electrical connectors and release any pin-type retainers attached to the seat cushion pan. 4. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers attached to the seat cushion and pan assembly. Disconnect the two heated seat cushion element electrical connectors from the backrest heated seat element. Item 17: Seat Track-to-Cushion Seat Pan Bolts Disassembly Note 1. NOTE: Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Remove the seat cushion pan bolts and remove the seat cushion assembly. Item 18: Seat Cushion Trim Cover Disassembly Note 1. Release the J-clips. 2. Remove all the seat cushion hog rings (two shown) and remove the seat cushion trim cover. Page 6228 Note: The bussed electrical center is located in the engine compartment. Page 6400 Page 6024 Starter Relay: Testing and Inspection Page 593 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation Electronic Throttle Control Module: Description and Operation TORQUE BASED ELECTRONIC THROTTLE CONTROL (ETC) Overview The Generation II (Gen II) Torque Based Electronic Throttle Control (ETC) is a hardware and software strategy that delivers a transmission output shaft torque (via throttle angle) based on driver demand (pedal position). It utilizes an electronic throttle body, the PCM and a accelerator pedal assembly to control throttle opening and engine torque. The ETC system basically replaces the standard cable operated accelerator pedal, idle air control (IAC) motor, 3-wire throttle position sensor (TPS) and mechanical throttle body Background "Why Torque Based ETC" 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: VCT (deliver same torque during transitions) - Hybrid Electric Vehicle (HEV) Torque based ETC also results is a less intrusive vehicle and engine speed limiting, along with smoother traction control. Other generic benefits of ETC are: Eliminate cruise control actuators - Eliminate Idle Air Control (IAC) Bypass actuator - Better airflow range - Packaging (no cable) - More responsive powertrain at altitude and improved shift quality It should be noted that the ETC system includes a wrench light on the instrument cluster that illuminates when a fault is detected. Faults are also accompanied by DTCS and the "Check Engine Soon" light. Electronic Throttle Body (ETB) The Gen II electronic throttle body (Figure 133) has the following characteristics 1. The DC motor is driven by the PCM (requires two wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are two designs; parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing (in general this is more difficult to package). The in-series design has a separate motor housing that protrudes out and offers more packaging flexibility. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle with no power applied. This is for limp home reasons (force of plunger spring is 2 times stronger than the main spring). Default angle is usually set to result in a top vehicle speed of 30 MPH (48 Km). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to avoid the throttle from binding in the bore (approximately 0.75 degree). This hard stop setting is non-adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable type throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle and idle quality and eliminates the need for IAC bypass actuator. 6. The system has two throttle position sensors. Redundant throttle position signals are required for monitor reasons. TP1 has a negative slope (increasing angle, decreasing voltage) and TP2 has a positive slope (increasing angle, increasing voltage). During normal operation the negative sloped TP sensor (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires four wires. 5 V Reference Voltage - Signal Return (ground) - TP1 voltage with negative voltage slope (5-0) - TP2 voltage with positive voltage slope (0-5) Accelerator Pedal Position Sensors (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, Heated Oxygen Sensor (HO2S) #22 Page 8812 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Description and Operation EGR Tube: Description and Operation Orifice Tube Assembly Orifice Tube Assembly The orifice tube assembly (Figure 94) 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 two 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. Service and Repair Seals and Gaskets: Service and Repair Differential Fluid Seals Special Tool(s) Material Removal and Installation NOTE: The removal of the seal is removed in two pieces. When installing the seal it is installed as one piece. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove both halfshafts. Locations View 151-5 Page 8643 NOTE: - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - When installing a new occupant classification sensor (OCS) service kit, refer to Air Bag Systems for the OCS service kit installation procedure. - Power seat is shown, manual seat is similar. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions the supplemental restraint system (SRS) deactivation/reactivation procedure. Deactivate the supplemental restraint system (SRS). 3. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes, and instructions in the seat removal and installation procedure. Remove the passenger seat. Page 4265 Page 9315 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 8784 Page 3674 Three-Way Catalytic Converter The three-way catalytic (TWC) converter contains either platinum (Pt) and rhodium (Rh) or palladium (Pd) and rhodium (Rh). The TWC converter catalyzes the oxidation reactions of unburned HCs and CO and the reduction reaction of NOx. The three-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. Heated Oxygen Sensors (HO2S) The HO2S provide the powertrain control module (PCM) with voltage and frequency information related to the oxygen content of the exhaust gas. (Refer to the PCM Inputs for a description of how the HO2S operates.) 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 it also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Page 7586 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 467 Inspection Page 8381 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 9237 Specifications Intake Manifold: Specifications Lower Intake Manifold Torque Sequence Lower Intake Manifold bolts Stage 1 ................................................................................................................................................ ................................................. 5 Nm (44 inch lbs.) Stage 2 ............................................................... ................................................................................................................................ 10 Nm (89 inch lbs.) Upper Intake Manifold Torque Sequence Upper Intake Manifold bolts Stage 1 ................................................................................................................................................ ................................................ 6 Nm (53 inch lbs.). Stage 2 ............................................................... ............................................................................................................................... 10 Nm (89 inch lbs.). Description and Operation Throttle Full Open Switch: Description and Operation WIDE OPEN THROTTLE A/C CUT-OFF (WAC) The wide open throttle A/C cutoff relay (may be referred to as the A/C clutch relay) is wired normally open (normally closed for Aviator). There is no direct electrical connection between the A/C switch or EATC Module and the A/C clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will check other A/C related inputs that are available (such as ACP (SW), ACCS). If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant temperature, engine rpm, throttle position), the PCM will ground the WAC output (unground for Aviator), closing the relay contacts and sending voltage to the A/C clutch. Page 9761 Page 7905 Page 1102 Inspection Left Page 754 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R70W For diagnosis of code P0755 refer to chart Part 5 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Page 2052 Adjustments Front Door Window Glass: Adjustments DOOR WINDOW GLASS ADJUSTMENT 1. Remove the front door trim panel and watershield. 2. Partially lower the front door window glass to within three inches of the full up position. 3. Loosen the nut and washer assemblies. 4. Open the front door. 5. Gently pull the front door window glass fully rearward into the door top glass run. 6. Tighten the nut. 7. NOTE: If the hole is a vertical slotted hole, make sure that the nut and washer assembly is positioned at the bottom of the slot before downward pressure is applied to the window regulator equalizer arm bracket. Apply downward pressure on the window regulator equalizer arm bracket. Service and Repair Page 8460 Trim Panel: Service and Repair Liftgate Trim Panel LIFTGATE TRIM PANEL REMOVAL 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION Page 5440 Recall - P/S Low Pressure Line Defect Technical Service Bulletin # 03S09 Date: 031101 Page 3025 22. Reconnect the battery ground cable. Reactivation Procedure WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions, and notes at the beginning of the deactivation procedure. NOTE: Make sure the battery negative cable is disconnected before proceeding with the reactivation portion of this procedure. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 3. Connect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the driver safety belt buckle pretensioner electrical connector. 2 Slide and engage the driver safety belt buckle pretensioner electrical connector locking clip. 4. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the driver seat side air bag module electrical connector. 5. Connect the driver seat side air bag module electrical connector, located beneath the seat. 1 Connect the driver seat side air bag module electrical connector. 2 Slide and engage the driver seat side air bag module electrical connector locking clip. 6. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the driver side safety canopy module electrical connector. 7. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, connect the driver side safety canopy module electrical connector. 8. Install the coat hook near the LH C-pillar trim panel. 9. Install the LH C-pillar trim panel. 10. Remove restraint system diagnostic tool 501-097 from the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 11. Connect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Connect the passenger safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger safety belt buckle pretensioner electrical connector locking clip. 12. Remove restraint system diagnostic tool 418-133 from the vehicle harness side of the passenger seat side air bag module electrical connector. 13. Connect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Connect the passenger seat side air bag module electrical connector. 2 Slide and engage the passenger seat side air bag module electrical connector locking clip. 14. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger side safety canopy module electrical connector. 15. Install the RH D-pillar trim panel. 16. Remove restraint system diagnostic tool 418-F403 from the vehicle harness side of the passenger air bag module electrical connector. 17. Through the glove compartment opening, connect the passenger air bag module electrical connector. 18. Close the glove compartment. 19. Remove restraint system diagnostic tool 418-F403 from the clockspring side of the driver air bag module electrical connector. 20. Through the steering wheel access door opening, connect the driver air bag module electrical connector. 21. Close the steering wheel access door. 22. Reconnect the battery ground cable. 23. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Procedures For Repair SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION Page 742 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0750 refer to chart Page 7034 4. NOTE: When correctly assembled, the male and female fittings should be flush. Assemble the male and female fittings together. Page 2534 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR REMOVAL 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9042 9. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the passenger side safety canopy module electrical connector. 10. Disconnect the passenger seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the passenger seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger seat side air bag module electrical connector. 11. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the passenger seat side air bag module electrical connector. 12. Disconnect the passenger safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the passenger safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger safety belt buckle pretensioner electrical connector. 13. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the passenger safety belt buckle pretensioner electrical connector. 14. Remove the LH C-pillar trim panel. 15. Remove the coat hook near the LH C-pillar trim panel. 16. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 17. Attach restraint system diagnostic tool 418-F403 to the vehicle harness side of the driver side safety canopy module electrical connector. 18. Disconnect the driver seat side air bag module electrical connector, located beneath the seat. 1 Slide and disengage the driver seat side air bag module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver seat side air bag module electrical connector. 19. Attach restraint system diagnostic tool 418-133 to the vehicle harness side of the driver seat side air bag module electrical connector. 20. Disconnect the driver safety belt buckle pretensioner electrical connector, located beneath the seat. 1 Slide and disengage the driver safety belt buckle pretensioner electrical connector locking clip. 2 Push in to release the tab and disconnect the driver safety belt buckle pretensioner electrical connector. 21. Attach restraint system diagnostic tool 501-097 to the vehicle harness side of the driver safety belt buckle pretensioner electrical connector. 22. Remove the affected seat(s). Connector Views Engine Control Module: Connector Views Locations View 151-6 Page 2333 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Page 211 Inspection Page 2391 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. 3. To install, reverse the removal procedure. Diagrams Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION NOTE: - Some vehicles are equipped with adjustable brake and accelerator pedals. These pedals are serviced as an assembly. - Care should be exercised when carrying out service on or around the accelerator pedal linkage and controls. 1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may cause binding. 3. Inspect the engine idle speed adjustment to make sure of correct idle speed specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for excessive wear or damage. Page 4610 Evaporative Check Valve: Service and Repair FUEL VAPOR CONTROL TUBE ASSEMBLY VALVE REMOVAL WARNING: - The evaporative emission system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, which can cause a fire or explosion if fuel vapor or liquefied fuel are present in the area. Failure to follow these instructions may result in personal injury. - Do not smoke or carry lighted tobacco or 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 personal injury. 1. Remove the fuel tank. 2. Remove the parts in the order indicated in the illustration and table. Item 3: Vapor Tube Quick-Connect Fittings Removal Note Page 6533 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 6342 Note: The bussed electrical center is located in the engine compartment. Page 2589 Special Tool(s) Page 7428 Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and carry out the diagnostic procedure again. - The left side is shown, the right side is similar. - The first row side impact sensors are located under the seat beneath the carpet. 1. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors or RCM, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located under the hood latch bracket. The first row side impact sensors (if equipped) are located under the seat, beneath the carpet. The second row side impact sensors (if equipped) are located at or near the base of the C-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Disconnect the battery ground cable and wait at least one minute. 2. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, notes, and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure. Refer to Air Bag(s) Arming and Disarming. Page 1593 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Page 7810 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Page 3339 1. NOTE: If the oil pan is not installed within four minutes, remove the sealer and reapply. Clean and apply sealant to the oil pan sealing areas shown and install the oil pan rear seal. 1. Apply silicone gasket and sealer to the rear main bearing cap. 2. Install the rear oil pan seal. 3. Apply a bead of silicone gasket and sealer to the oil pan mating surface. Oil Pan Torque Sequence 2. Install the oil pan and start the bolts. - Tighten the oil pan bolts in the order shown. Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE SENSOR Typical Engine Oil Temperature (EOT) Sensor The engine oil temperature (EOT) sensor (Figure 35) is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and 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. Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The EOT sensor measures the temperature of the engine oil. The sensor is typically threaded into the engine oil lubrication system near the oil filter or screwed into the oil pan. The PCM can use the EOT sensor input to determine the following: - On Variable Cam Timing (VCT) applications the EOT input is used to adjust the VCT control gains and logic for camshaft timing. - The PCM can use EOT sensor input in conjunction with other PCM inputs to determine oil degradation. - The PCM can use EOT sensor input to initiate a soft engine shutdown. To prevent engine damage from occurring as a result of high oil temperatures, the PCM has the ability to initiate a soft engine shutdown. Whenever engine RPM exceeds a calibrated level for a certain period of time, the PCM will begin reducing power by disabling engine cylinders. Page 1108 P1385 - P1389: Testing and Inspection P1386 For diagnosis of code P1386 refer to chart P1336-P1477 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 2100 Page 5261 Item 3: Transmission Selector Cable Grommet Removal Note 1. Press the lock tabs and push the transmission selector cable through the bulkhead. Item 4, 5 and 6: Transmission Selector Cable End and Retainer Removal Note 1. Remove the two screws and the instrument panel lower steering column opening cover. 2. Separate the LH instrument panel finish panel from the instrument panel. 3. Remove the RH instrument panel finish panel. Page 1942 Page 7966 Disclaimer Page 1737 ABS - Module Replacement Service Tip Hydraulic Control Assembly - Antilock Brakes: All Technical Service Bulletins ABS - Module Replacement Service Tip TSB 04-12-5 6/01/04 DIAGNOSTIC TROUBLE CODE (DTC) C1991 (MODULE CALIBRATION FAILURE) - ANTI-LOCK BRAKE, ADVANCED TRAC, INTERACTIVE VEHICLE DYNAMICS (IVD), TRACTION CONTROL SYSTEM - SERVICE TIP FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE When replacing the ABS module a code C1991 will be set. This is due to the new module not being calibrated. Proper calibration procedures must be followed to successfully clear the C1991. The new ECU will not complete a successful module calibration if other codes are present, and will keep resetting code C1991. DTC C1991 will be set if: ^ Other anti-lock brake system, traction control/IVD related codes are present during the calibration process. ^ Calibration setup criteria are not met. ^ Module is not calibrated. ACTION All other ABS related system conditions and/or DTC's must be resolved before module replacement and module calibration. If the vehicle exhibited a condition and trouble code related to pressure transducer, YAW sensor, brake booster, or steering angle sensor, perform appropriate pinpoint tests and diagnostics. Repair any wiring, connector, and/or sensor issues before module replacement. After the booster, SWA, YAW/LAT, or ECU has been replaced, the ECU will need to be calibrated. Refer to the following Service Procedure. SERVICE PROCEDURE Freestar/Monterey module calibration can be performed using the NGS or WDS scan tools. MODULE CALIBRATION USING WDS With the brake pedal released, select the following: 1. Toolbox. 2. Chassis. 3. Braking. MERCURY: 2004-2005 Monterey 4. IVD Initialization Sequence. 5. Ensure that requirements on screen are met for the input you are about to calibrate, then press Confirm. 6. Select YAW Rate/Lateral Acceleration Calibration and follow on-screen prompts. YAW Sensor Calibration requirements ^ Vehicle in park. ^ Key on. Page 7472 3. CAUTION: - Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS service kit components (hose, pressure sensor, electronic control unit wire harness, and connectors) through the seat cushion pan opening. 4. CAUTION: Inspect the occupant classification sensor assembly, seat cushion pan and support assembly for any foreign objects before installing the occupant classification sensor assembly to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad with OCS bladder to the seat cushion pan and set in place. 5. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Attach the seat cushion trim cover J-clips to the seat cushion pan. If equipped with heated seats, connect the cushion element electrical connector. Page 5639 Inspect the body sealant on the bulkhead to ensure it is not protruding out causing the cover not to seal properly in that area. (Figure 2) If sealant is interferring with the PCM cover, remove excess with a sharp tool. Reinstall the PCM cover ensuring the cover seals and is flush with the bulkhead. 1. Remove the wiper pivot arm. (Figure 3) a. Release pivot arm nut cover. b. Remove the pivot arm nut. c. Remove the pivot arm. 2. Remove the screws. (Figure 4) 3. Release the clips. 4. Remove the windshield wiper hose. P1635 P1635 - P1639: Testing and Inspection P1635 For diagnosis of code P1635 refer to NOTE 21: NOTE 21: See DTC description and causes. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1181 P1500 - P1504: Testing and Inspection P1502 For diagnosis of code P1502 refer to chart P1479-P1640 NOTE 8: Vehicle speed information is provided by the anti-lock brake system. Go to Antilock Brakes / Traction Control Systems. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection NOTE 18: All Automatic Transmissions go to Transmission Control Systems. See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 3447 3. Using the special tools, install the crankshaft front seal. Item 8: Crankshaft Pulley Installation Note 1. Lower the RH side of the subframe 50.8 mm (2 inch) - Remove the bolts. - Lower the subframe. 2. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley. Using the special tool, install the crankshaft pulley. 3. Raise the subframe into position, then install the bolts. 4. Connect the RH front anti-lock brake wheel sensor electrical connector. Page 3072 Note: The bussed electrical center is located in the engine compartment. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION SENSORS (APPS) The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are three pedal position sensors required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 & APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are two VREF wires, two signal return wires and three signal wires (total of seven wires and pins) between the PCM and APPS assembly. - 2-5 V Reference Voltage - 2- Signal Return (ground) - APP1 voltage with negative voltage slope (5-0) - APP2 voltage with positive voltage slope (0-5) - APP3 voltage with positive voltage slope (0-5) 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. Electronic Throttle Body And Accelerator Pedal Assembly 4. The three pedal position signals ensure a correct input to the PCM, if any one signal has a fault. The PCM knows if a signal is wrong by calculating where it should be, inferred by the other signals. A value will be substituted for a faulty signal if two out of the three signals are bad. Page 13 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Brakes - Rear Caliper Leaks (Mexico Vehicles Only) Brake Caliper: All Technical Service Bulletins Brakes - Rear Caliper Leaks (Mexico Vehicles Only) TSB 06-14-11 07/24/06 REAR BRAKE CALIPER LEAKS (VEHICLES SOLD IN MEXICO ONLY) - SERVICE TIP FORD: 2004-2006 Freestar MERCURY: 2004-2006 Monterey ISSUE 2004-2006 Freestar / Monterey vehicles may exhibit rear brake caliper fluid leaks - Service Tip. ACTION The rear brake caliper fluid leaks could be fluid seepage that may occur under certain conditions. Wetness around the piston seal is acceptable and should merely be wiped clean without any required repairs. SERVICE PROCEDURE If fluid accumulates enough that it causes dripping, then replace the brake caliper with the part that has been recently updated in service. Refer to Workshop Manual, Section 206-04, Rear Disc Brake. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 1109 07 Disclaimer Page 3968 Typical "Drop-in" Mass Air Flow (MAF) Sensor The mass air flow (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 ambient temperature as measured by a constant cold wire (Figure 42). If the hot wire electronic sensing element must be replaced, then the entire assembly must be replaced. Replacing only the element may change the air flow calibration. The current required to maintain the temperature of the hot wire is proportional to the air mass flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. Most MAF sensors have integrated bypass technology (IBT) with an integrated intake air temperature (IAT) sensor. The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner assembly. Page 4361 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pan, Oil Pump Screen and Pickup Tube, Oil Pan Baffle Material Material CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the starter. 3. Remove the dual converter Y-pipe. 4. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Page 8453 Part 2 3. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Overhead Console Removal Note 1. Unclip the console and disconnect the electrical connectors. Item 2: Headliner Electrical Connector(s) Removal Note 1. If the headliner is not equipped with an overhead console the electrical connector will located behind the LH windshield side garnish moulding. Disconnect the electrical connector(s). Item 6: Sun Visor Removal Note 1. Disconnect the electrical connectors. Item 9: Safety Belt Trim Panel Removal Note 1. Position the safety belt buckle through the panel. Item 14: Headliner Removal Note 1. Folding the headliner will require the installation of a new headliner. Item 15: Washer Solvent Hose Removal Note 1. WARNING: Windshield washer solvent contains methanol which is poisonous. Observe all cautions and warnings indicated on the label of the washer solvent container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling washer solvent, drain the hose before removal. Disconnect the washer solvent hose from the front and rear of the headliner. INSTALLATION 1. To install, reverse the removal procedure. Locations Page 6688 8. Install the coat hook cover. 9. Install the C-pillar trim panel. 1 Position and install the C-pillar trim panel. 2 Attach the quarter trim panel. 3 Attach the weather-strip. 10. Position the safety belt guide and install the bolt. 11. Install the safety belt guide cover. All vehicles Page 4729 Item 7: Air Cleaner Cover Installation Note 1. NOTE: No tools are needed to install the air cleaner cover. Installation should be carried out using hands only. Use the alignment notches to correctly align the air cleaner cover to the air cleaner tray. Engine Controls - MAF Sensor Diagnostic Service Tip Air Flow Meter/Sensor: Technical Service Bulletins Engine Controls - MAF Sensor Diagnostic Service Tip TSB 05-3-1 02/21/05 MAF DIAGNOSTIC SERVICE TIP - VEHICLES EQUIPPED WITH EGR SYSTEM MODULE (ESM) FORD: 2003-2005 Crown Victoria, Thunderbird 2005 Five Hundred, Ford CT, Freestyle, Mustang 2004-2005 Explorer, F-150, Freestar 2005 E-Series LINCOLN: 2003-2005 LS, Town Car, Aviator MERCURY: 2003-2005 Grand Marquis 2005 Montego 2004-2005 Monterey, Mountaineer ISSUE When diagnosing for a possible MAF sensor related condition, on a vehicle equipped with an EGR system module (ESM), an incorrect engine-running BARO value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM. ACTION Refer to the following Service Tips to aid in diagnosing MAF and other malfunction indicator lamp (MIL)/driveability concerns, using the BARO PID. SERVICE TIPS NOTE SOME EARLY BUILT 2003 VEHICLES EQUIPPED WITH AN ESM MAY NOT HAVE THE STRATEGY/CALIBRATION TO UPDATE THE BARO PID USING THE ESM'S MAP SENSOR. IN THESE APPLICATIONS THE BARO WILL BE UPDATED BY THE MAF SENSOR, OR IF FAULTS ARE PRESENT A DEFAULT VALUE WILL BE SET (DEFAULT VALUE MAY DIFFER DEPENDING ON APPLICATION AND STRATEGY). DIAGNOSE THESE APPLICATIONS WITH THE CURRENT PROCEDURES WITHOUT USING THE ESM'S BARO METHODS. Locations View 151-6 Page 8111 8. Use heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing. 9. Reconnect battery ground cable. Page 7888 View 151-18 Page 9191 Brake Lamp: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 8157 Trailer Connector: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Locations View 151-10 Page 7019 Page 637 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1689 Locations View 151-8 Page 1208 P1515 - P1519: Testing and Inspection P1519 For diagnosis of code P1519 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 4196 Throttle Plate Controller Check Operation The purpose of the TPPC is to control the throttle position to the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle signal. The TPPC interprets the duty cycle signal as follows: 0% <= DC < 5% - Out of range, limp home default position. - 5% <= DC < 6% - Commanded default position, closed. - 6% <= DC < 7% - Commanded default position. Used for key-on, engine off. - 7% <= DC < 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - 10% <= DC <= 92% - Normal operation, between 0 degrees (hard-stop) and 82%, 10% duty cycle = 0 degrees throttle angle, 92% duty cycle = 82 degrees throttle angle. - 92% < DC <= 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - 96% < DC <= 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate to be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The "H" driver is capable of positive or negative voltage to the Electronic Throttle Body Motor. Page 8494 View 151-18 Page 8277 Power Sliding Door Module: Testing and Inspection POWER SLIDING DOOR MODULE SELF-TEST WARNING: During the PSD self-test, the PSD will attempt to fully open and close the PSD. The PSD self-test does not require the PARK and VSS signal to open the door. Do not carry out the PSD self-test with the vehicle in motion. The PSD self-test will attempt to power open and close the PSD. As the PSD is opened and closed, the PSD monitors the system for correct inputs. Upon completing the self-test, DTCs will be logged for any incorrect operations. The PSD also checks the following inputs during a self-test: - overhead console on/off switch circuit - overhead console open/close switch/RKE circuits - B-pillar switch circuit - PARK (enable) circuit from the SJB - vehicle speed circuit from SJB - fuel filler door circuit (left PSD only) The PSD has the ability to reverse the PSD operation if certain conditions exist. This is a normal function of the system, however some electrical concerns may cause the same symptom. If the PSD reverses during operation or during the self-test, always check for an obstruction or misalignment first. If no obstruction or misalignment is found, make sure to complete all DTC and symptom diagnostics. Initialization Procedure If the PSD loses the logic battery supply for any reason, such as battery disconnect, module disconnect or if left open for more than 6 hours, the PSD will lose the PSD position stored in memory. Disconnecting the battery will cause both PSDs to lose PSD position. Disconnecting the PSD connector will only cause the specific module to lose its memory. If only one PSD module is affected, the initialization procedure only needs to be carried out for the specific module. The PSD normal operation will not be restored until the PSD position is once again stored into memory. The initialization procedure is the learning process the PSD uses to restore the PSD position in memory. The PSD monitors the position sensor data received during the initial power open-and-close operation to learn the positions. Refer to Power Sliding Door Initialization. Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Front Parking Aid Speaker Parking Assist Warning Indicator: Service and Repair Front Parking Aid Speaker PARKING AID SPEAKER - FRONT REMOVAL 1. Remove the RH instrument panel steering column reinforcement. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9438 Trailer Lighting Relay: Testing and Inspection Trailer Tow Relay, Left Turn Page 2784 9. Install the special tool on the spring lock coupling at the fuel supply manifold. 10. Close and push the special tool into the open side of the cage. 11. Separate the fuel tube fitting. 12. Release the special tool. Page 9176 Page 7915 BLOCKED/CONTAMINATED PROXIMITY SENSOR SURFACE: Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is contaminated with any foreign material the system may sound a continuous tone or intermittent tone. The sensor surface can be cleaned by a high pressure water spray. SIDE COVERAGE SENSOR: There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large, extending obstacle such as a garage wall. If there is no encroachment between any of the outer sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the obstacle begin to move closer to each other, then the warning will begin again. Obstacles within 10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal operation. ABNORMAL ROAD SURFACES: The RSS/FSS may give warnings due to certain road surfaces with surface projections such as rocks, broken pavement, unplowed snow covered roads. This is considered normal operation. OTHER POSSIBLE CAUSES: Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External ultrasonic noise may be detected (high velocity air, machinery). This is considered normal operation. SENSOR DIAGNOSTICS 1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and within 6' (1.8 meters) of the front of the vehicle for the FSS. 2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high pressure water to ensure that the membrane gap is free of any dirt or contamination. 3. Using the New Generation Star (NGS) tester (up to 2004 MY), NGS+ (2005 MY) or WDS observe the following four parking aid module parameter identification displays (PIDs) for distance information: ^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle) ^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle) ^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle) ^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle) NOTE PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED. a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches (NGS+ and WDS). Bussed Electrical Center (BEC) Fuse: Application and ID Bussed Electrical Center (BEC) Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH Transmission Control Switch (TCS) Transmission Control Switch (TCS) The transmission control switch (TCS) (Figure 50) and (Figure 51) signals the PCM with keypower whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle controls the position of the TCS. Page 827 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 386 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Engine Controls, A/T - Various Driveability Issues/DTC's Cowl: Customer Interest Engine Controls, A/T - Various Driveability Issues/DTC's TSB 06-14-10 07/24/06 ENGINE/TRANSMISSION DRIVEABILITY ISSUES FORD: 1999-2003 Windstar 2004-2007 Freestar MERCURY: 2004-2007 Monterey This article supersedes TSB 05-23-7 to update the Service Procedure and model years. ISSUE Some 1999-2003 Windstar and 2004-2007 Freestar / Monterey vehicles built prior to 6/22/2006 may exhibit engine / transmission driveability issues due to water entering the powertrain control module (PCM) or transaxle vent. Symptoms may include various diagnostic trouble codes (DTCs), harsh or delayed transmission shifts I engagements, no reverse engagement, engine overheat, engine lean condition causing a misfire (possibly leading to melted electrodes on the spark plugs), and rough idle. The water leakage may be due to the PCM connector cover not seating completely and water leaking down from the cowl panel grille (cowl top vent panel) area. ACTION During normal diagnostic and repair procedures, inspect for evidence of water damage at the PCM, PCM connector, and/or transaxle. If present, inspect the sealing area of the PCM cover, seal the water leak path in the cowl panel grill area, and service the PCM as needed per the following Service Procedure. SERVICE PROCEDURE Disconnect the PCM connector. Remove the PCM cover from the studs in the bulkhead. (Figure 1) Page 4513 Page 9565 Page 8218 Sliding Door Margin Specifications 8. NOTE: The margin is the gap between two adjoining panels. Inspect the sliding door. Measure the margins of the sliding door according to the specifications. 9. If the sliding door to front door margin does not meet specifications or if the door requires horizontal or vertical adjustment, adjust the lower roller bracket as follows: 1 Remove the bolt plug cover from the lower corner of the sliding door trim panel. 2 Mark the door around the lower roller bracket to measure the adjustment increments. 3 NOTE: The lower roller bracket and guide assembly bolts should be loosened enough to allow the assembly to move, but not so loose that the assembly cannot hold its position when moved. Loosen the lower roller bolts. 4 Use a nylon hammer to adjust the hinge up or down. Make sure that the front door margin is equal and within specification at the top and bottom. 5 Close the sliding door and check for correct fit. Readjust if necessary. Page 9216 - high mounted stoplamp - SJB Test H PINPOINT TEST H: THE STOPLAMPS ARE ON CONTINUOUSLY Test H1-H4 Page 7310 ^ View and Record DTC XXXXX Fault PIDs (2007 WSM) ^ DataLogger/View and Record DTC XXXXX Fault Pids (2008 and future WSMs) In each instance the direction is the same (view fault PIDs to identify the specific component and fault condition) but how they are accessed by the scan tools, as well as the scan tool terminology, will vary. FLAG the DTC - View the Fault PIDs For example, the "Flag" DTC feature is specific to NGS/NGS+. When using IDS/PDS it is necessary to view the fault PIDs from DataLogger. Using IDS/PDS NOTE WHEN USING IDS/PDS, MOVE THE CURSOR OVER THE PID OR SELECT THE PID TO DISPLAY ITS DEFINITION AT THE BOTTOM OF THE SCREEN. WHEN USING PDS, HIGHLIGHT OR MOVE THE STYLUS OVER THE PID TO SEE THE PID DEFINITION. 1. Perform a self test of the RCM and/or OCS module to retrieve on-demand and continuous memory DTCs. 2. To view the fault PIDs associated with an on-demand DTC: a. Toolbox b. DataLogger c. Modules d. RCM 3. Monitor all "_OD" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". ^ For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_OD PID reads "FAULT' indicating a front internal crash sensor fault. 4. To view the fault PIDs associated with a continuous memory DTC: a. Toolbox b. DataLogger c. Modules d. RCM 5. Monitor all "_CM" PID(s) matching the DTC present; follow diagnostic procedure for the PID that reads "FAULT". For example, a B2296 fault is present. In DataLogger the fault PID 2296_18_CM PID reads "FAULT" indicating a front internal crash sensor fault. IDS/PDS Fault PID Naming Conventions The fault PIDs as displayed on IDS/PDS uses a strategy associating it with the DTC. For example, the fault PIDs 2296_18_OD and 2296_18_CM break down as follows: ^ 2296 - The DTC number minus the "B" (body) or "C" (chassis) designation. ^ 18 - An identifier used to distinguish between each of the fault PIDs associated with the DTC. ^ OD - Identifies the fault PID as an on-demand fault. ^ CM - Identifies the fault PID as a continuous memory (intermittent) fault. NOTE THE DTCS AND FAULT PIDS SUPPORTED BY A VEHICLE WILL VARY DEPENDING ON VEHICLE EQUIPMENT. Specifications Brake Bleeding: Specifications Bleeder screws .................................................................................................................................... ........................................................ 10 Nm (7 ft. lbs.) Power Seat Motor Assembly, Left View 151-16 Page 1424 P2070 - P2074: Testing and Inspection P2072 For diagnosis of code P2072 refer to NOTE 26: NOTE 26: Refer to Trouble Code Descriptions - Diagnostic Aids for DTC P2072 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Powertrain Control Module (PCM) Reset Engine Control Module: Service and Repair Powertrain Control Module (PCM) Reset POWERTRAIN CONTROL MODULE (PCM) RESET Description All OBD II scan tools support the powertrain control module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. For more information about a drive cycle, refer to Drive Cycles. See: Testing and Inspection/Monitors, Trips, Drive Cycles and Readiness Codes/Drive Cycles The following events occur when a PCM reset is performed: Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. Resetting Keep Alive Memory (KAM) Resetting Keep Alive Memory will return PCM memory to its default setting. Adaptive learning contents such as idle speed, refueling event, and fuel trim are included. A PCM Reset (described above) is also part of a KAM Reset. Both can be useful in post repair retest. After Keep Alive Memory has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. This function may not be supported by all scan tools. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Page 3933 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8735 Page 262 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P0201 refer to chart Locations View 151-6 Page 1495 P2270 - P2274: Testing and Inspection P2271 For diagnosis of code P2271 refer to chart P2107-Pxxxx If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 6914 Blower Motor Relay: Testing and Inspection Auxiliary Blower Speed Relay 1 Page 9186 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 2705 View 151-6 Differential Pressure Feedback EGR System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR System DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR Differential Pressure Feedback EGR Sensor The differential pressure feedback EGR sensor (Figure 90) 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 sensor receives this signal through two 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 that 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. Page 646 P0705 - P0709: Testing and Inspection P0707 For diagnosis of code P0707 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4704 Accelerator Pedal: Diagnostic Aids Troubleshooting wiring harness and connector hidden concerns The 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 in each illustration. NOTE: Several components, such as the Powertrain Control Module (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 terminals by pulling each wire at the end of the connector. Page 8116 Symptom Chart Page 9556 Test W8-W10 Page 1380 Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: Locations View 151-8 Page 7866 Alarm System Transponder: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER REMOVAL 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 9392 92-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 5198 ^ Windstar Freestar and Monterey (Figure 3, 4, and 5) Taurus and Sable with column shifter (Figure 6) Page 8084 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 7277 Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure PROVE OUT PROCEDURE Turn the ignition switch from the OFF to the ON position and visually monitor the air bag indicator with all SRS components connected or restraint system diagnostic tools installed. The air bag indicator will light continuously for approximately six seconds and then turn off. If an SRS fault is present, the air bag indicator will either: - 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 restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 4147 4. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 8: Power Steering Pump Bolts Removal Note 1. The bolt that is positioned under the power steering pressure line fitting will remain with the pump. Item 11: Camshaft Synchronizer Removal Note 1. The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding. Page 6753 Part 3 Of 3 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. Item 1: Axle Shaft Nut Removal Note 1. Remove and discard the axle shaft nut with the vehicle on the ground. 2. Using the special tools, remove the front driveshaft and Joint from the wheel hub. Page 9759 Windshield Washer Switch: Diagrams Page 499 P0440 - P0444: Testing and Inspection P0443 For diagnosis of code P0443 refer to chart P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3026 Special Tool(s) SPECIAL TOOL(S) Deactivation WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Never probe the connectors on the safety canopy module. Doing so can result in safety canopy deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. NOTE: - If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if equipped) system is being serviced, the air bag system must be deactivated. - Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if equipped) and safety belt pretensioner (if equipped) to floor connectors. - Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors. The restraint system diagnostic tools must be removed prior to operating the vehicle over the road. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - After diagnosing or repairing a seat system, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles Page 4195 Electronic Throttle Monitor Operation, Part 1 Electronic Throttle Monitor Operation, Part 2 Accelerator and Throttle Position Sensor Inputs Accelerator Pedal Position Sensor Check Accelerator Pedal Position Sensor Check: Throttle Position Sensor Check Throttle Position Sensor Check: Throttle Plate Position Controller (TPPC) Outputs Page 338 P0260 - P0264: Testing and Inspection P0262 For diagnosis of code P0262 refer to chart B1219-B1317 / P0182-P1272 Page 662 P0710 - P0714: Testing and Inspection P0713 Torqshift For diagnosis of code P0713 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Service Precautions Hose/Line HVAC: Service Precautions CAUTION: Refrigerant compressor oil (mineral oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to the R-134a refrigerant system as an A/C compressor lubricant. PAG refrigerant compressor oil F7AZ-19D589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant. Page 8776 View 151-17 Page 7528 3. Select "RCM RESTRAINT CTRL MOD" and press Trigger. 4. Select "PID / DATA MONITOR and RECORD" and press Trigger. 5. Select the following PIDS and press Trigger, (all 12 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". b. D_ABAG2, "DRVR SIDE AIRBAG RESISTANCE ND CNT". c. DBAGL2, "DRVR AIRBAG LOOP 2 RESIST". d. D_PRTNR, "DRVR PRETENSIONER CKT RES". e. DCURTL1, "DRIVER CURTAIN LOOP 1 RESISTANCE". f. DCURTL2, "DRIVER CURTAIN LOOP 2 RESISTANCE". g. PCURTL1, "PASSENGER CURTAIN LOOP 1 RESISTANCE". h. PCURTL2, PASSENGER CURTAIN LOOP 2 RESISTANCE". i. P_ABAGR, "PSGR AIRBAG RESISTANCE". j. PBAGL2, "PSGR AIRBAG LOOP 2 RESIST". k. P_ABAG2, "PSGR SIDE AIRBAG RESISTANCE ND CNT". l. P_PRTNR, "PSGR PRETENSIONER CKT RES". If one or more PID measurement reads 0 Ohms, identify and repair the airbag firing loop circuit(s) that are shorted to other firing loop circuit(s). DO NOT replace the RCM again. SERVICE PROCEDURE - VEHICLES WITHOUT SIDE AIRBAGS 1. Disconnect the forward (front) impact severity (crash) sensor and attempt to clear the B1342 DTC. a. If the B1342 clears and only a B2296 remains, replace the front impact severity sensor. Clear DTCs and return the vehicle to the customer. b. If DTC B1342 is still present after disconnecting the front impact sensor and after attempting to clear DTCs, proceed to Step 2. 2. Check circuits to the impact sensor for shorts to ground, verify power and ground circuits to RCM. a. If concerns are found, repair wiring as necessary, clear DTCs and return vehicle to the customer. b. If no power or ground related faults are found, replace the RCM. Clear DTCs and return vehicle to the customer. (1) If B1342 is present after replacing RCM, a cross-circuit (short) between airbag or pretensioner firing loops may be the cause. Proceed to CROSS - CIRCUIT SHORT DIAGNOSIS. CROSS-CIRCUIT SHORT DIAGNOSIS USING NGS - VEHICLES WITHOUT SIDE AIRBAGS 1. Select the appropriate "Vehicle and Engine Selection". 2. Select "DIAGNOSTIC DATA LINK" and press trigger. 3. Select "RCM - RESTRAINT CTRL MOD" and press trigger. 4. Select "PID / DATA MONITOR and RECORD" and press trigger. 5. Select the following PIDS and press trigger, (all 9 can be selected at once). a. D_ABAGR, "DRVR AIRBAG RESISTANCE". Page 7466 1. Release the recliner handle cover tab and remove the cover. Item 9: Side Air Bag Module Connector Removal Note 1. If equipped, separate the side air bag module electrical connector and wire harness from the seat riser and cushion pan. Item 10: Climate Control Seat Duct Removal Note 1. If equipped, separate the climate control duct and disconnect the backrest thermal electric device electrical connector. 2. If equipped, disconnect the two seat backrest heated seat element electrical connectors. Item 13: Connectors Removal Note 1. If equipped, disconnect and separate the electrical connectors and wire harnesses necessary to remove the seat cushion assembly. Item 15: Seat Cushion Assembly Removal Note 1. Remove the seat cushion assembly. - Disconnect and release any remaining electrical connectors and pin-type retainers necessary to separate the seat cushion pan from the seat track and riser. Item 16: Seat Cushion Trim Cover Removal Note 1. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Release the seat cushion trim cover J-clips from the seat cushion pan. If equipped, disconnect the seat cushion heated seat element electrical connector. Description and Operation Fuel Gauge Sender: Description and Operation FUEL PUMP MODULE Fuel Pump Module Page 9134 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module (Figure 71),(Figure 72) and(Figure 73) is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 8182 Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061410A 2004-2007 1.0 Hr. Freestar/Monterey, 1999-2003 Windstar: Inspect And Seal The Cowl Panel Grill Area (Do Not Use With 17526A, 17566A, 17508A, 17603A) MT061410 Claim Additional Labor Actual Required As Actual Time Time Or Use SLIS Operation If Available DEALER CODING CONDITION BASIC PART NO. CODE 7002030 68 Disclaimer Page 1667 P1746 P1745 - P1749: Testing and Inspection P1746 For diagnosis of code P1746 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 6455 LH Side Power Sliding Door Module: Diagrams LH Side Page 5460 Item 7: Selector Lever Indicator Cable Removal Note 1. Position the selector lever indicator cable aside. 1 Loosen the screw. 2 Disconnect the cable. 3 Position the selector lever indicator cable aside. Technician Safety Information Fuel Filler Hose: Technician Safety Information WARNING: - Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. - The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, and possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. - Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard. - Do not use an open flame to heat the heat shrink tube, only use a heat gun. Page 6406 Page 5502 3. Loop the jumper harness once and connect male end of jumper into female seat motor connector (Figure 3). 4. Tuck the jumper harness loop between seat pan and seat wire harness (Figure 4). 5. Position the jumper loop close to seat harness (Figure 5). Page 5707 Brake Pedal Assy: Connector Views Page 7856 Antenna, Radio: Service and Repair Removal and Installation ANTENNA REMOVAL NOTE: - The antenna is a conductive trace integral to the right rear quarter-glass and can be repaired, but not installed separately. For removal and installation of the quarter-glass, refer to Trim Panel. For repair procedures, refer to Antenna Grid Wire Repair. - The antenna cable is not serviceable. It is integral with the interior harness. 1. Disconnect the battery. 2. Remove the upper RH rear quarter panel trim panel. 3. Remove the parking aid speaker. 4. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8483 Keyless Entry Key-Pad: Service and Repair Removal And Installation KEYLESS ENTRY KEYPAD REMOVAL 1. Remove the front door trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8359 Connector Views Radiator Cooling Fan Motor: Connector Views P0201 P0200 - P0204: Testing and Inspection P0201 OBD II - Base Gasoline For diagnosis of code P0201 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 1990 Page 2764 Special Tools Page 4949 Throttle Cable/Linkage: Service and Repair ACCELERATOR CABLE AND BRACKET REMOVAL 1. If removing the accelerator cable bracket, remove the air cleaner outlet tube. 2. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Accelerator Cable Grommet Removal Note Page 2516 Page 7336 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 8942 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 Page 715 Part 8 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0740 refer to chart Page 3061 Page 520 P0455 - P0459: Testing and Inspection P0456 For diagnosis of code P0456 refer to the system experiencing the problem. Computers and Control Systems P0400-P0462 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 5329 21. Install the air cleaner tube and tighten the clamps. 22. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive shift strategy. Connect the battery. 23. Fill the transaxle assembly with one quart of clean automatic transmission fluid. 24. Start the engine. Move the transaxle range selector lever through all positions. Check the fluid level. For additional information, refer to Fluid Level and Condition Check under Preliminary Inspection. Page 5826 Brake Caliper: Specifications Front Brake caliper anchor bracket bolts ................................................................................................................................................... 185 Nm (136 ft. lbs.) Caliper bolts .............................................................................................................. ........................................................................... 35 Nm (26 ft. lbs.) Rear Brake caliper anchor bracket bolts ..................................................................................................................................................... 102 Nm (75 ft. lbs.) Caliper bolts ................................................................................................................ ......................................................................... 33 Nm (24 ft. lbs.) Service and Repair Seat Belt Height Adjuster: Service and Repair SAFETY BELT SHOULDER HEIGHT ADJUSTER WITH STRIPPED WELD NUTS D-Ring Installation Kit SPECIAL TOOL(S) 1. Remove the height adjuster; refer to Front Safety Belt or Rear Safety Belt-Bench Seat, Second Row, Rear Safety Belt-Bucket Seat, Second Row. 2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the damaged threads in the upper pillar structure. 3. NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any chips before proceeding. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation Kit and tap new threads. 4. Use a threaded insert provided in D-Ring Installation Kit and screw it into the retapped hole until it is slightly below the surface. Page 8906 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 7667 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 7898 The perimeter lighting feature requests the headlamps and parking/position lamps to be on when the key is in the OFF position and the customer activates an external unlock feature (remote transmitter, keyless entry keypad, door lock cylinder). The perimeter lighting feature requests the headlamps and park/position lamps to be off when 25 seconds have elapsed since the last external unlock activation, or the customer activates an external lock feature (remote transmitter, keyless entry keypad), or the key is cycled to a position other than OFF. P0055 P0055 - P0059: Testing and Inspection P0055 For diagnosis of code P0055 refer to chart Bxxxx / C172x-Cxxxx / P0010-P0109 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - P1285 P1285 - P1289: Testing and Inspection P1285 For diagnosis of code P1285 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 3839 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 4590 Typical Bank 1 Catalyst Two HO2S Configuration Typical Bank 1 Catalyst Three HO2S Configuration The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe before the catalyst. The catalytic converter reduces the concentration of carbon monoxide (CO), unburned hydrocarbons (HCs) and oxides of nitrogen (NOx) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter through another HO2S mounted in the rear exhaust pipe (Figure 124) and then on into the muffler. Lastly, the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. Note on some Partial Zero Emission Vehicles (PZEV), there will be a total of 3 HO2S in the exhaust stream. One near the exhaust manifold (stream 1), one in the middle of the light-off catalyst (stream 2) and the third (stream 3) is mounted after the light-off catalyst (Figure 125). 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 two 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 that vehicle. Page 1812 5. Remove the upper cowl panel grille. 6. Disconnect the electrical connector. (Figure 5) 7. Remove the lower cowl panel assembly. (Figure 6) a. Remove the ten (10) bolts. b. Remove the lower cowl panel assembly. 8. Obtain two (2) PVC soft foam adhesive stripes (164-R4901) from the Rotunda Squeak And Rattle Kit (164-R4900). 9. Cut both of the PVC soft foam adhesive stripes in half, lengthwise, so you have four (4) pieces 7/8" x 6" (22 mm x 152 mm). (Figure 7) 10. Clean the metal body surface under the lower cowl panel, in the area above the transaxle and the area above the PCM. Page 6917 Page 4049 3. If removing the ignition coil, remove the wiper motor and pivot assembly. 4. Remove the parts in the order listed in the illustration and table. To remove individual parts, only carry out the listed steps. Item 2: Spark Plug Wire-to-Ignition Coil Removal Note 1. CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires. NOTE: Spark plug wires must be connected to the correct ignition coil terminal. Disconnect the six spark plug wires. Page 9634 Page 9737 Page 9675 8. Tighten the nut. 9. Cycle the front door window glass to make sure of correct operation. Readjust the height if necessary. 10. Install the front door trim panel and watershield. Electrical - ABS/TCS/Park Brake Lamps Flickering ABS Light: Customer Interest Electrical - ABS/TCS/Park Brake Lamps Flickering TSB 04-23-1 11/29/04 TRACTION CONTROL, ABS AND PARK BRAKE LAMPS FLICKER/FLASH/ILLUMINATE FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 2004-2005 Freestar/Monterey vehicles (excluding vehicles built with the memory seat feature) may exhibit the traction control, anti-lock brake system (ABS) and park brake lamps flashing/flickering/illuminating in the instrument cluster. The condition occurs when the front power seats (driver or passenger seat) are operated. The condition is due to transient electrical noise generated by the power seat motor. ACTION Install a seat motor jumper harness to correct the condition. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Disconnect the seat motor wiring outboard connector by unlocking the larger tab and pulling the male connection out (Figure 1). 2. Connect the male end of the seat motor connector to female end of jumper harness (Figure 2). Page 9602 Page 6325 Page 6715 Part 1 Of 2 Page 6157 Page 9632 Page 7808 - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause safety system failure. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 2. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining ear is completely engaged. - When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining ear. 3. CAUTION: Inspect the occupant classification sensor bladder, seat cushion pan and support assembly for any foreign objects, before installing the occupant classification sensor to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Align the bladder to the seat cushion pan. Item 5: Electronic Control Unit (ECU) Installation Note 1. Slide the electronic control unit (ECU) into the seat cushion pan bracket and install the rivets. - The ECU must be correctly positioned and securely riveted in place. Failure to do so can set a diagnostic trouble code (DTC) in the restraints control module (RCM). Item 8: Seat Cushion Trim Cover Installation Note 1. CAUTION: - Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. Item 9: Seat Cushion Foam Pad Installation Note 1. CAUTION: Inspect the seat cushion pad and pan for any foreign objects before installing the seat cushion pad to the seat cushion pan. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Position the seat cushion foam pad to the seat cushion pan and set in place. 2. CAUTION: It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. Page 6496 System Diagnosis P1225 - P1229: Testing and Inspection For diagnosis of code P1229 refer to chart P1151-P1309 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3320 Part 3 Of 3 To remove individual parts, only carry out the listed steps: 5. To install, reverse the removal procedure. Item 5: RH Engine Mount Nut Removal Note 1. Using the special tools, raise the engine. Item 11: LH Engine Mount Bolt Removal Note 1. NOTE: The A/C compressor must be repositioned to access the LH engine mount bolt. Loosen the A/C compressor mounting bolts 25.4 mm (1 inch), then slide the A/C compressor toward the front of the vehicle. Item 11: LH Engine Mount Bolt Installation Note Page 6324 Page 9265 Fog/Driving Lamp Relay: Testing and Inspection Page 1983 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Locations View 151-8 Page 8282 View 151-20 Page 7089 4. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps. Item 10: Heater Hose Removal Note 1. Clamp off and disconnect the heater hoses at the heater core. Item 16: Heater Core Removal Note Page 2026 Page 8625 Page 2841 Symptom Chart Page 1765 The ETC monitor system is distributed across two processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an Enhanced-Quizzer (E-Quizzer) processor. The primary monitoring function is performed by the Independent Plausibility Check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by specified amount, the IPC takes appropriate mitigating action. ETC System Failure Mode And Effects Management, Part 1 ETC System Failure Mode And Effects Management, Part 2 Since the IPC and main controller share the same processor, they are subject to a number of potential, common failure modes. Therefore, the E-Quizzer processor was added to redundantly monitor selected PCM inputs and to act as an intelligent watchdog and monitor the performance of the IPC and the main processor. If it determines that the IPC function is impaired in any way, it takes appropriate Failure Mode and Effects Management (FMEM) actions. Electronic Throttle Monitor Operation: Page 4243 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 9059 12. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. 13. Connect the passenger seat safety belt buckle pretensioner electrical connector. 1 Connect the passenger seat safety belt buckle pretensioner electrical connector. 2 Slide and engage the passenger seat safety belt buckle pretensioner electrical connector locking clip. Vehicles with safety canopies and seat side air bags 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. 15. Connect the passenger seat side air bag electrical connector. 1 Connect the passenger seat side air bag electrical connector. 2 Slide and engage the passenger seat side air bag electrical connector locking clip. Page 3684 Torque Sequence RH 1. Tighten the exhaust manifold nuts in the sequence shown. Master Window/Door Lock/Unlock Switch Power Door Lock Switch: Diagrams Master Window/Door Lock/Unlock Switch Page 9369 System Overview Each major vehicle system includes a complete system overview diagram prior to each set of diagrams. It is important to realize that this is only a high level overview of the complete system connectivity. It includes component operational information (1), component name and base part number (2), and basic component internals (3). It does not include specific circuit information, connector or pin numbers, splices or grounds. That information is found on the subsequent diagrams in the set. Page 4004 Trailer Tow Relay, Parking Lamp Page 2013 Door Position Switch: Locations View 151-14 Page 1513 P2700 - P2704: Testing and Inspection P2703 For diagnosis of code P2703 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 1052 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1273 refer to chart Page 5302 Transmission Position Switch/Sensor: Service and Repair Digital Transmission Range (TR) Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parts in the order indicated in the following illustration and table. 3. To install, reverse the removal procedure. 4. Verify that the shift cable is correctly adjusted. For additional information, refer to Selector Lever Cable Adjustment. Page 3901 View 151-5 Page 8945 1. Disconnect battery ground cable. 2. Strip wires to appropriate length. 3. Install 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. Page 3738 11. Apply Motorcraft(R) Ultra Silicone Sealant around all four sides of the gray header where it meets the PCM sheet metal. (Figure 9) NOTE ALLOW 1 HOUR FOR SEALANT TO DRY PRIOR TO INSTALLING PCM. 12. Install the PCM in the vehicle. Refer to WSM, Section 303-14. NOTE ONLY 2006-2007 MODEL YEAR FREESTAR AND MONTEREY VEHICLES NEED TO HAVE THE PCM REPROGRAMMED. FOR THESE VEHICLES ONLY, PROCEED TO STEP 13. 13. Reprogram the powertrain control module (PCM) to the latest calibration using IDS release 49.9 and higher or 50.1 and higher. This new calibration is not included in the VCM 2007.7 DVD. Calibration files may also be obtained at the website. Parts Block 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. OPERATION DESCRIPTION TIME 100303A 2004-2005 Freestar, 0.9 Hr. Monterey: Check DTCs, Inspect PCM For Water Intrusion, And Modify Existing PCM Following Service Procedure (Do Not Use With Any Other Labor Operations) Page 9232 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 6187 Page 3420 Timing Chain Tensioner: Service and Repair Engine Front Cover, Timing Gears, Chain and Tensioners Special Tools And Equipment Special Tool(s) Material Material Page 7549 Air Bag Control Module: Vehicle Damage Warnings CAUTION: - Installing a J-nut in place of a weld nut is not a recommended repair. - Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. - Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. - Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. Auxiliary Relay Box Page 3270 3. Lower the RH side of the subframe 50.8 mm (2 inch). - Remove the bolts. - Lower the subframe. Item 6: Crankshaft Pulley Removal Note 1. Using the special tool, remove the crankshaft pulley. Item 7: Crankshaft Front Seal Removal Note 1. Using the special tool, remove the front crankshaft front seal. Item 7: Crankshaft Front Seal Installation Note 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft front seal lips with clean engine oil prior to installation. Page 6522 1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2, taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut off the end and re-strip. 2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced. Twist wires together. Solder wires together (Figure 4). NOTE USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER FOR WIRE REPAIR. 3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond. NOTE WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES. Page 6650 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 2B373 42 Disclaimer Page 1401 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8044 Page 8291 Power Sliding Door Motor: Service and Repair DRIVE ASSEMBLY ACTUATOR REMOVAL 1. Open the power sliding door. 2. Open the rear quarter window. 3. Remove the CJB fuse 11 (15A). 4. For LH-side drive assembly actuator, remove the upper and lower A/C ducts. 5. For RH-side drive assembly actuator, remove the upper quarter trim panel. 6. NOTE: Right side shown, left side similar. Remove the parts in the order indicated in the illustration and table. To remove individual parts, only carry out the listed steps. Item 1: Screw Removal Note ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 Hydraulic Control Assembly - Antilock Brakes: Customer Interest ABS/TCS - ABS/TCS Indicators ON/ABS Activates/DTC C1288 TSB 07-14-10 07/23/07 TRACTION CONTROL LAMP - ABS LAMP - ABS SELF ACTIVATION WITH DTC C1288 FORD: 2004-2005 Freestar MERCURY: 2004-2005 Monterey This article supersedes TSB 05-6-17 to update the Service Procedure. ISSUE Some 2004-2005 Freestar and Monterey vehicles may exhibit a traction control indicator on, anti-lock brake system (ABS) indicator on, and/or self ABS activation with a diagnostic trouble code (DTC) C1288. ACTION It may be necessary to replace the ABS module the hydraulic control unit (HCU), or the brake pressure switch. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE DTC C1288 IS PRESENT ALONG WITH OTHER DTCS, REPAIR THE OTHER CODES FIRST BEFORE CONTINUING WITH THIS TSB. 1. First perform normal diagnostics per Workshop Manual, Section (WSM) 206-09. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present, proceed to Step 2. 2. Ensure that the latest ABS module is installed. a. If the prefix starts with "4" (4F23 or 4F2Z) proceed to Step 3. b. If the prefix starts with "5" or "6" proceed to Step 4. 3. Install latest level ABS module. When installing, check for water on the circuit board and/or in the aluminum cavity of the HCU. If water is present, replace the HCU as well. Refer to WSMI, Section 206-09 for removal and installation procedures. Perform IVD calibration sequence. a. If the concern is corrected, return the vehicle to the customer. b. If the concern is still present and only the ABS module was replaced, proceed to Step 4. c. If the concern is still present and both the ABS and HCU were replaced, proceed to Step 5. 4. Monitor the brake pressure transducer (MPRETDR) PID using IDS. The KOER PID reading should be fluctuating with no brake pedal applied, this is normal. Lightly apply the brake pedal and the PID reading should increase with brake pedal pressure and decrease as you release the brake pedal. a. If the brake pressure transducer does not operate as described, replace the HCU assembly. If the concern is corrected, return the vehicle to the customer. b. If the brake pressure transducer does operate as described, or if concern is still present after HCU replacement, proceed to Step 5. 5. Replace the brake pressure switch (BPS) at the master cylinder. Page 1557 Power Sliding Door Module: Diagrams RH Side System Diagnosis P0645 - P0649: Testing and Inspection For diagnosis of code P0645 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Locations View 151-17 Page 8077 Symbols Part 5 Page 2509 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH REMOVAL 1. Remove the jack access cover on the RH side interior rear quarter trim panel. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8748 Locations View 151-3 Door Ajar Switch, Left Front View 151-18 Page 8639 Part 1 Page 1920 1. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. 3. NOTE: The RCM has been removed for clarity. Page 6541 6. Secure jumper loop to seat harness with tie strap (Figure 6). 7. Clear any diagnostic trouble codes (DTC's) that may have been generated. Verify fix by moving both the driver seat and the passenger seat one at a time. Watch the instrument cluster to see if warning lights flicker/illuminate. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042301A Install The Seat Jumper 0.4 Hr. Harness DEALER CODING CONDITION BASIC PART NO. CODE 14B067 42 Disclaimer Page 1371 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 4717 127-3 Diagrams: Other diagrams referred to by number (See Diagram ##-#, 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 Component Location Views. See: Diagrams/Components/Component Location Views Page 2296 Headlamp Dimmer Switch: Diagrams Rear View 151-26 Page 238 P0190 - P0194: Testing and Inspection P0192 OBD II - Base Gasoline For diagnosis of code P0192 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 8782 Page 9053 20. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat safety belt buckle pretensioner electrical connector. Vehicles with safety canopies and seat side air bags NOTE: If the headliner near each B-pillar and the outboard side of the front seat backrest trim cover has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules and seat side air bag modules. 21. Pull out at the top and remove the driver side second row safety belt guide cover. 22. Remove the driver side second row safety belt guide bolt and safety belt guide. 23. Remove the trim panel. 1 Separate the weather-strip. 2 Separate the quarter trim panel at the C-pillar trim panel. 3 Remove the C-pillar trim panel. Page 128 - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel LPG Only For diagnosis of code P0131 refer to chart Page 5253 Page 2046 View 151-19 Locations View 151-29 Heated Oxygen Sensor (HO2S) #22 Page 1512 P2700 - P2704: Testing and Inspection P2702 For diagnosis of code P2702 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 642 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection 4R100 For diagnosis of code P0705 refer to chart If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 120 P0125 - P0129: Testing and Inspection P0127 For diagnosis of code P0127 refer to chart P0112-P0147 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9322 Symbols Part 4 Page 8274 Door Lock Actuator Assembly, Left Sliding Door Locations View 151-10 Page 9362 92-2 Page 339 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Customer Safety Information Air Bag Control Module: Customer Safety Information WARNING: - The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. Page 2999 Refrigerant Oil: Service Precautions CAUTION: 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 refrigerant oil will go with the component. To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part. Page 510 Inspection Page 975 Inspection Page 9021 - liftgate ajar - check left headlamp - check right headlamp - low brake fluid - check left turn lamps - check right turn lamps - check brake lamps - check left parking lamps - check right parking lamps - washer fluid low - check traction control - check fuel cap - change oil soon - oil change required - check tire - turn signal on The repetitive warning messages will display whenever the key is turned to ON or a fault occurs in a system. These can be cleared by pressing the RESET button. Repetitive warning messages will re-appear again after a 10-minute interval until the condition is corrected. The repetitive warning messages are: parking brake set - check brake system - reduced engine power - stop engine safely - transmission overheated The non-resettable warning messages display whenever the key is turned to ON and a fault occurs in a system. The fault must be corrected to clear the non-resettable warning messages. The non-resettable warning messages are: driver door ajar - passenger door ajar - driver rear door ajar - passenger rear door ajar Temporary Alert Messages The temporary alert display will interrupt the current display to show the status of an event that has just happened. The temporary alert messages are: traction control active Page 9457 Brake Light Switch: Service and Repair STOPLAMP SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 287 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 5946 Page 6718 4. To assemble, reverse the disassembly procedure. 5. After installing the steering gear in the vehicle, adjust the front toe. Item 1: Tie-Rod End Disassembly Note 1. Index-mark the tie-rod end to the tie-rod end jam nut and to the spindle tie-rod. Item 6: Spindle Tie-Rod Disassembly Note 1. CAUTION: To resist rotation and prevent damage to the steering gear during removal of the spindle tie-rods, center the steering gear and position the rack gear in a soft-jawed vice. Remove the spindle tie-rod. Item 7: Check Valve Disassembly Note 1. Remove the check valve located in the upper hose port. Item 6: Spindle Tie-Rod Assembly Note 1. CAUTION: To resist rotation and prevent damage to the steering gear during removal of the spindle tie-rods, center the steering gear and position the rack gear in a soft-jawed vice. Install the spindle tie-rod. Item 4: Inner Bellows Clamp Assembly Note 1. Using the special tool, Install the clamps. Page 6761 ^ Engine not running. ^ Vehicle on level surface. 7. Select Brake Booster/Steering Wheel Angle Calibration and follow on-screen prompts. Steering Angle Sensor Calibration requirements ^ Engine running. ^ Turn steering lock to lock. EAS Booster Calibration requirements ^ Vehicle in park. ^ Engine running. ^ Brake not applied. MODULE CALIBRATION USING THE NGS 1. Use NGS green service card version 12.4 or greater. 2. Select new vehicle "2004 Freestar/Monterey". 3. Main menu trigger on "Service Bay Functions". 4. Trigger on "ABS". 5. Trigger on "IVD Calibration". 6. NGS message indicates "Prepare Vehicle For Test/Function", ensure that the following requirements are met: ^ Vehicle is on level surface. ^ Start the vehicle and let idle. ^ Steering wheel is centered. a. Push the trigger button. 7. NGS will automatically go through calibration process steps 7a and 7b, Step 7c must be performed manually. a. Calibrates YAW/LAT Sensor Cluster. b. Proceeds to Booster Learn. c. Steering Wheel Angle Sensor, MANUALLY turn steering wheel full left and right (lock to lock). NOTE WHEN THE CALIBRATION PROCEDURE PASSES A MESSAGE WILL APPEAR INDICATING "VEHICLE CALIBRATION COMPLETE". 8. Press cancel to back out to main menu, turn vehicle off, restart vehicle. 9. Use the NGS red diagnostic card and clear codes. 10. Road test the vehicle to verify fix. NOTE IF NGS DISPLAYS A MESSAGE INDICATING: "DETERMINING ABS PROTOCOL- PLEASE WAIT" OR "FAILED BOOSTER LEARN" DURING THE AUTOMATIC CALIBRATION PROCESS, OR NGS KEEPS CANCELING THE CALIBRATION PROCESS, THIS MEANS THERE IS A SYSTEM FAULT/CODE PRESENT AND/OR THE ORIGINAL CONDITION HAS NOT BEEN RESOLVED. Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER REMOVAL NOTE: - When any new lock cylinder is installed, the door lock cylinder(s) and ignition lock cylinder are installed as a set. This eliminates carrying an extra key which fits only one lock. If a new key is used, the new key code number is stamped on a metal tag attached to the key. - Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Disconnect the battery. 2. Remove the parts in the order indicated in the illustration and table. Page 29 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection P1130 P1130 - P1134: Testing and Inspection P1130 For diagnosis of code P1130 refer to chart P0723-P1150 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 9054 24. Pry out at the side and remove the coat hook cover. 25. Remove the screw and the coat hook. 26. From between the headliner and the roof of the vehicle, just to the front of the C-pillar, disconnect the driver side safety canopy module electrical connector. 27. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Page 4092 1. CAUTION: - Spark plug wires must be connected correctly. - It is important to twist the spark plug wire boots while pulling along the axis of the spark plug to avoid possible damage to the spark plug wires. With a twisting motion, use the special tool to pull the six spark plug wires from the spark plugs. Item 7: Spark Plugs Removal Note 1. Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. INSTALLATION 1. To install, reverse the removal procedure. Item 7: Spark Plugs Installation Note 1. Adjust the spark plug gap as necessary. Item 6: Spark Plug Wire-to-Spark Plug Installation Note 1. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold. Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs. Page 2343 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 285 P0205 - P0209: Testing and Inspection P0208 OBD II - Base Gasoline For diagnosis of code P0208 refer to chart P0192-P0223 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 81 For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 7556 Connect the large RCM electrical connector. - Using the connector position assurance lever, pivot it toward the RCM, drawing the connector into the RCM. Make sure the thumb tab is engaged to the retainer on the RCM and locked in place. Page 1032 - For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection OBD II - BI-Fuel CNG Only For diagnosis of code P1266 refer to chart Body - Cowl Panel Grille Breakage Cowl: Customer Interest Body - Cowl Panel Grille Breakage TSB 04-17-6 09/06/04 COWL PANEL GRILL BREAKING FORD: 1999-2003 Windstar 2004-2005 Freestar MERCURY: 2004-2005 Monterey ISSUE Some 1999-2003 Windstar and 2004-2005 Freestar/Monterey vehicles may exhibit the windshield cowl panel grille (leaf screen) breaking at the grille opening. ACTION To service, replace cowl panel with updated service part. Refer to Workshop Manual Section 501-02. PARTS BLOCK WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 041706A Replace The 0.3 Hr. Windshield Cowl Panel Grille (Leaf Screen) DEALER CODING CONDITION BASIC PART NO. CODE 70022A68 01 Disclaimer Page 1600 NOTE FOR AN INTERMITTENT C1288, MONITOR (MPRETDR) PID DATA WHEN THE CODE SETS, LOOK FOR INTERFERENCE FROM ELECTRIC MOTORS (SUCH AS WINDSHIELD WIPERS OR POWER SEATS). REPLACE THE ABS MODULE FOR THIS CONDITION. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME 071410A 2004-2005 0.6 Hr. Freestar/Monterey Replace Anti Lock Brake Module (Includes Time To Configure Module, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410B 2004-2005 1.2 Hrs. Freestar/Monterey Replace Anti Lock Brake Module And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module And Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410C 2004-2005 1.8 Hrs. Freestar/Monterey Replace The Anti Lock Module And HCU (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410D 2004-2005 1.9 Hrs. Freestar/Monterey Replace The Anti Lock Module, HCU, And Brake Pressure Switch (Includes Time To Perform Diagnosis, Configure Module, Bleed Brake System, Clear Codes) (Do Not Use With 2219D, 2219D6, 2219D11, 12650D) 071410E 2004-2005 0.9 Hr. Freestar/Monterey Replace The Brake Pressure Switch (Includes Time To Perform Diagnosis, Bleed Brake System, Clear Codes) (Do Page 3100 Relay Box: Locations Smart Junction Box (SJB) Note: The fuse panel is located below and to the left of the steering wheel by the brake pedal. Page 5643 19. Install four (4) new pushpin screw/rivets to secure the upper cowl to the lower cowl. Add Clear Silicone Rubber to the four (4) pushpin screw/rivets to make a watertight seal around them. (Figure 14) 20. Add Clear Silicone Rubber to the front seam between the upper and lower cowl in the area above the transaxle. (Figure 15) 21. Install wiper pivot arms. (Figure 16) NOTE APPLY THREADLOCK TO THE PIVOT ARM NUT. 22. Check the wiper pivot arm adjustment. Page 628 P0660 - P0664: Testing and Inspection P0663 For diagnosis of code P0663 refer to chart P0505-P0722 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code - Page 7471 Disarming/Service and Repair/Prove Out Procedure 11. Check the active restraint system for correct operation. 12. NOTE: When installing a new occupant classification sensor, a prepaid return postcard is provided with the new occupant classification sensor. The serial number for the new part and the vehicle identification number (VIN) must be recorded and sent to Ford Motor Company. Fill out the necessary information on the occupant classification sensor traceability card and return it along with the complete inoperative occupant classification sensor to Ford Motor Company. When returning the inoperative occupant classification sensor, include the following: seat cushion foam pad, bladder, electronic control unit, pressure sensor (transducer), hose, electrical connectors and wire harness (service part occupant classification sensor only). Item 1: Occupant Classification Sensor (OCS) (For OCS Service Kit) Installation Note 1. Bend the tab back on the pressure sensor component bracket. 2. CAUTION: Inspect the seat cushion pad and seat cushion trim cover for any foreign objects, before installing the seat cushion trim cover to the seat cushion pad. If any foreign objects are found, remove them. Failure to do so may result in personal injury, in the event of an air bag deployment. Using hog rings, attach the seat cushion trim cover to the seat cushion foam pad. If equipped with heated seats, make sure the wire harness is accessible after trim cover attachment. Page 7133 Refrigerant: Testing and Inspection Electronic Leak Detection ELECTRONIC LEAK DETECTION H10PM Refrigerant Leak Detector With Battery SPECIAL TOOL(S) CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing. 1. NOTE: The system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off. Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions included with the leak detector for handling and operation techniques. 2. If a leak is found, recover the refrigerant. - Repair the system. - Test the system for normal operation. Page 7358 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR The passenger air bag deactivation (PAD) indicator is a visual indicator used to inform the front seat occupants of the passenger air bag deactivation state. The PAD indicator is a stand-alone lamp installed into the vehicle instrument panel in a position visible to each front seat occupant. The restraints control module (RCM) controls the state of the PAD indicator through a direct hard-wire connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is ON to indicate the passenger air bag module is deactivated (OFF). Some exemptions to this are made in certain scenarios such as when the front passenger seat is determined to be empty, and therefore indication of a deactivated passenger air bag module is not necessary. In all cases the PAD indicator is OFF when the passenger air bag module is activated (ON). When the ignition switch is in the ON position, the PAD indicator prove-out period is initiated by the RCM. The RCM briefly activates the PAD indicator to prove-out the indicator function and verify to the front occupants proper functional operation of the PAD indicator. The PAD indicator will illuminate/not illuminate within 1.0 + 0.5 seconds of a change of state from the OCS system. When an OCS system fault is present the SRS defaults the passenger air bag module to ON (activated) regardless of the size of the occupant in the front outboard passenger seat. The PAD indicator will be OFF. Passenger Air Bag And PAD Indicator Status The table indicate the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant. Page 4217 14. Remove and discard the two rubber plugs on the bottom of the cowl sheet metal. (Figure 11) 15. Install the lower cowl panel and 10 retaining bolts. (Figure 12) 16. Connect the electrical connector. (Figure 13) 17. Install the upper cowl panel grille. 18. Install the windshield wiper hose. Page 7350 1. Make sure the connector position assurance lever is in the full release position before attempting to connect the connector. 2. CAUTION: Putting the large RCM electrical connector into the RCM on an angle can cause bad electrical connections and damage components. NOTE: The RCM has been removed for clarity. Position the large RCM electrical connector into the RCM. - CAUTION: Do not push the connector on to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. 3. NOTE: The RCM has been removed for clarity. Page 9375 Symbols Part 3 Page 9326 3 Female half 4 Seal 5 Intermittent contact 6 Male half 7 Intermittent contact 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. Page 1190 P1505 - P1509: Testing and Inspection P1507 For diagnosis of code P1507 refer to chart P1479-P1640 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Page 6402 Paint Codes Paint: Application and ID Paint Codes The Vehicle Certification Label (VC) is located on the left-hand front door jamb. Exterior paint codes may be listed as a two-part code. The first set of characters listed indicate the vehicle primary body color. The second set of characters listed (if applicable) indicate a two-tone or accent body color. All codes are base coat/clear coat. Primary Body Color Code - AQ Arizona Beige - C2 Gold Ash Metallic - DT Matador Red - FS Spruce Green - KR Norcea Blue - SP Medium Steel Blue - SU Amazon Green Pearl - JP Silver Birch Metallic Page 9266 Page 2077 View 151-17 Page 272 P0182-P1273 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 8531 Description and Operation Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING SYSTEM Overview Variable Cam Timing (VCT) enables rotation of the camshaft(s) relative to the crankshaft (phase-shafting) as a function of engine operating conditions. There are four 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 four operational modes; idle, part throttle, wide open throttle and default mode. At idle and low engine speeds with closed throttle, the phase angle are controlled by air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM controls cam timing 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 improve torque. In addition, on some applications a VCT system can eliminated the need for an external Exhaust Gas Recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap in valve opening between the intake valve opening and exhaust valve closing. Currently for the 2004 model year, Ford Motor Company uses the PS and DEPS systems. The IPS system is on Lincoln LS, Thunderbird and Focus SVT and the DEPS system is on the F150 5.4L 3V. Variable Cam Timing Variable Cam Timing System The VCT (variable cam timing) system consists of an electric hydraulic positioning control solenoid, a CMP (camshaft position sensor) and trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A CKP (crankshaft position sensor) provides the PCM with crankshaft positioning information in 10 degree increments (Figure 115). 1. The PCM receives input signals from the IAT (intake air temperature), ECT (engine coolant temperature), EOT (engine oil temperature), CMP, TP (throttle position), MAF (mass air flow) and CKP to determine the operating conditions of the engine. At idle (low engine speeds and closed throttle) the PCM controls camshaft position based on air and coolant temperatures. During part and wide open throttle, camshaft position is determined by engine RPM, load and throttle position. The VCT system will not operate until the engine is at normal operating temperature. 2. The VCT system is enabled by the PCM when the proper 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 Page 3041 25. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 26. Through the steering wheel access door opening, connect the driver air bag module electrical connector and attach it to the retainer. 27. Close the steering wheel access door. 28. Connect the battery. 29. WARNING: Restraint system diagnostic tools are for service only. Tools must be removed prior to operating the vehicle over the road. Failure to remove restraint system diagnostic tools could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Prove Out Procedure Vehicles with safety canopies and seat side air bags 30. Check the active restraint system for correct operation. Page 6922 Blower Motor Resistor: Locations Front Blower Motor Resistor Assembly View 151-8 Page 6105 Page 3195 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. Raise the vehicle until the tires are off of the ground. 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the wheel and tire assembly. Grasp the tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire from the front wheel bearings. If movement exists, a new hub and bearing assembly must be installed. Page 8243 Front Door Window Motor: Service and Repair DOOR WINDOW MOTOR INITIALIZATION CAUTION: Make sure no obstructions are present in the window system when carrying out this procedure. NOTE: - Excessive bounce-back (bounce-back that occurs with no obstructions present) may indicate a non-initialized window motor. - The front window motors must be initialized whenever: the motor is removed from the window regulator, a new motor is installed, a new window regulator is installed, a new window glass is installed, a glass top run removal and installation and when carrying out any operation in which grease or lubricants are applied to the window system. A new front window motor will be in a proportional up/down mode until initialized. - All front window components (window glass, window regulator, window motor and glass top run) must be installed and tightened to specification before carrying out this procedure. - If this procedure is only partially completed, the front window motor will remain non-initialized and only the proportional up/down functions will operate. A non-initialized window motor may allow one-touch down operation, but will NOT allow one-touch up operation. - Steps 1 through 6 must be completed within 30 seconds. The entire procedure must be completed within five minutes. - Once the ignition key is turned to the ON position in Step 6, it must remain on until the entire procedure is completed. - Steps 7 and 9 require the applicable front window control switch be held in the UP position until the front window motor stalls the window glass into the glass top run. Step 8 requires the applicable window control switch be momentarily actuated to the DOWN position. 1. Start with the ignition key in the OFF position with the applicable front door open. 2. Turn the ignition key to the ON position. 3. Press the applicable front window control switch to the AUTO position six times (AUTO up or AUTO down). 4. Turn the ignition key to the OFF position and make sure the front door is open. 5. Press the front window control switch to the AUTO position six times (AUTO up or AUTO down). 6. Turn the ignition key to the ON position and close the front door. The front window glass will move up-down-up-down approximately 20 mm (0.8 in). This movement indicates the front window motor has entered initialization mode. 7. Press and hold the front window control switch to the UP position until the window glass stalls into the glass top run. 8. Momentarily press the front window control switch to the DOWN position and release. The window will carry out a one-touch down operation until the window glass stalls at the bottom of travel stop designed into the window regulator. 9. Press and hold the front window control switch to the UP position until the window glass stalls into the glass top run. Once this operation is complete, the front window glass will move up-down-up-down approximately 20 mm (0.8 in) indicating the front window motor has been successfully initialized. 10. Verify correct operation of the front window by carrying out a one-touch down, one-touch up, proportional down and proportional up operation. Page 3042 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist AIR BAG RECONNECT CHECKLIST The checklist below should be completed following diagnosis or repair of any air bag system concern: - All restraint system diagnostic tools removed? - All in-seat harness connectors connected? - Occupant classification sensor (OCS) system connected? - All air bag modules connected? - Safety belt pretensioner connectors connected? - Restraints control module (RCM) connected? - All sensors (front and side impact sensors, safety belt tension sensor) connected? - Battery connected? Page 704 For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Description and Operation EGR Valve: Description and Operation Exhaust Gas Recirculation Valve EGR Valve The EGR valve (Figure 93) in the Differential Pressure Feedback EGR system is a conventional, vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg). Since EGR flow requirement varies greatly, providing service specifications on flow rate is impractical. The on-board diagnostic system monitors the EGR valve function and triggers a Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the field diagnostic procedures. Page 7628 Part 2 4. Remove the parts in the order indicated in the illustrations and tables. Item 3: Lower B-Pillar Trim Panel Removal Note 1. To remove the B-pillar trim panel, move the front seat to its most forward position. Item 4: Height Adjuster Button Cover Removal Note 1. To remove the height adjuster button cover, squeeze the buttons and pull the cover from the bottom. Item 8: Upper B-pillar Trim Panel Removal Note 1. To remove the B-pillar trim panel, pull from the bottom of the panel with a steady pressure. Page 1676 Fog/Driving Lamp Relay: Testing and Inspection Page 1745 Page 6907 Page 8655 1 Release the cable from the anchor retainer. 2 Unclip the cable end. Item 26: Cushion Trim Cover Disassembly Note 1. Release the J-clips. 2. CAUTION: Use care when separating the seat upholstery from the hook and loop strip, or the hook and loop strip can be torn from the seat cushion foam pad. Separate the hook and loop fasteners. 3. Remove and discard all the hog rings and remove the seat cushion trim cover. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Third Row REAR SEAT CUSHION - THIRD ROW DISASSEMBLY 1. Remove the third row seat. 2. Open the third row seat to normal sitting position. Page 8724 Page 9488 Page 4402 Engine Control Module: Service and Repair Powertrain Control Module (PCM) Removal and Installation POWERTRAIN CONTROL MODULE (PCM) REMOVAL 1. Disconnect the battery ground cable. 2. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Service and Repair Parking Assist Switch: Service and Repair PARKING AID SWITCH REMOVAL 1. Remove the parts in the order indicated in the illustration and table. Item 1: Overhead Console Removal Note 1. The overhead console is held in place by spring clips located on the panel. Item 3: Parking Aid Switch Removal Note 1. Release the tabs and remove the parking aid switch. INSTALLATION 1. To install, reverse the removal procedure. Description and Operation Leak Detection Solenoid: Description and Operation CANISTER VENT SOLENOID Typical Canister Vent (CV) Solenoid During the EVAP Leak Check Monitor, the canister vent (CV) solenoid (Figure 105) seals the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP Leak Check Monitor. Page 3944 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor VEHICLE SPEED SENSOR Typical Vehicle Speed Sensor (VSS) The vehicle speed sensor (VSS) (Figure 52) is a variable reluctance or Hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch scheduling. Page 3375 Material Material 1. With the vehicle in neutral, position it on a hoist. 2. Remove the transaxle. 3. Remove the parts in the order indicated in the illustration and table. Part 1 Of 2 Part 2 Of 2 To remove individual parts, only carry out the listed steps: Item 3: Crankshaft Rear Seal Removal Note 1. Using the special tools, remove the crankshaft rear seal. Page 4715 Accelerator Pedal: 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. 127-1 Page 6991 Page 1738 System Diagnosis P1755 - P1759: Testing and Inspection For diagnosis of code P1756 refer to chart Part 4 Of 9 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain Management/Transmission Control Systems/Testing and Inspection Page 9255 View 151-22 Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Special Tool(s) SPECIAL TOOL(S) REMOVAL WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - The safety belt pretensioner is a pyrotechnic device. Always wear safety glasses when repairing an air bag equipped vehicle and when handling a safety belt buckle pretensioner or safety belt retractor pretensioner. Never probe a pretensioner electrical connector. Doing so could result in pretensioner or air bag deployment and could result in personal injury. - The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. CAUTION: - There are three occupant classification sensor (OCS) system service kits available for this vehicle (base seat, heated seat and climate controlled seat). Always make sure the correct OCS service kit is installed. - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, a seat side shield removed, or an OCS service kit is installed. A scan tool is used to trigger the active command to carry out rezeroing of the OCS system. NOTE: - The heated seat element on the front passenger seat cushion is not serviceable separately. If a new heated seat element is needed on the front passenger seat cushion a new occupant classification sensor (OCS) service kit, equipped with a heated seat element, must be installed. - Occupant classification sensor (OCS) system components (seat cushion foam pad, bladder with pressure sensor and electronic control unit) are calibrated to each other and are serviced as an assembly. The OCS system components are not to be installed separately. If a new OCS system, OCS system component or seat cushion foam pad are needed, a new OCS system service kit (seat cushion foam pad, bladder with pressure sensor and electronic control unit) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit) inspect the ECU electrical connector. A production OCS system allows the disconnect of the ECU electrical connector. A service OCS system (OCS service kit) has the ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. - If removing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Repair is made only by installing a new assembly. If the new assembly does not correct the condition, install the original equipment and carry out the diagnostic procedure again. Page 322 P0230 - P0234: Testing and Inspection P0232 For diagnosis of code P0232 refer to chart P0230-P0360 If there is no link in the chart then: - This code is not a valid code for this vehicle - Or information published by the manufacturer for this vehicle did not include this code Page 6886 1. Remove the parts in the order indicated in the illustration and table. INSTALLATION 1. To install, reverse the removal procedure. Page 8425 4. Disconnect the driver air bag module. 1 Push the driver air bag module electrical connector together. 2 Push down, pivoting the electrical connector and release the electrical connector retainer. 3 Pull out, disconnecting the vehicle harness end of the connector from the component end. 5. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. 6. Push in on the 2 glove compartment door tabs and position the glove compartment downward. Page 5859 Not Use With 2219D, 2219D6, 2219D11, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 9F924 42 Disclaimer Page 2950 Coolant: Fluid Type Specifications Motorcraft Premium Gold Engine Coolant VC-7-A (in California and Oregon VC-7-B) or equivalent (yellow-color) Ford Specification ................................................................................................................................ .................................................. HWSS-M97B51-A1 Note: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. Page 7345 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: The restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, a new RCM must be installed whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy modules and risk of personal injury. NOTE: When installing a new restraints control module (RCM), always make sure the correct RCM is being installed. If an incorrect RCM is installed, erroneous DTCs will result. The restraints control module (RCM) is mounted on the center tunnel under the instrument panel. The RCM carries out the following functions: supplies current flow to the inflators to deploy the air bags in the event of a deployable crash. - supplies current flow to the inflators to deploy the safety canopies in the event of a deployable crash. - activates the safety belt retractor pretensioners to remove slack from the safety belt. - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the lamp fault code (LFC) detected. - communicates through the data link connector (DLC) the current or historical diagnostic trouble codes (DTCs). - signals the instrument cluster module to activate a chime if the air bag indicator is not available and another SRS fault exists. - contains an internal safing sensor which is not serviced separately. - records deployment event data. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the LFC. The air bag indicator will flash the LFC three times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the (DLC), using a scan tool. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the instrument cluster module to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient current to deploy the front air bags and safety belt pretensioners in the event that the ignition circuit is damaged or lost in a collision before the RCM determines that air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Page 8477 View 151-18 Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ............................................................. 4.7L (5.0 Qt) Door Ajar Switch, Left Front View 151-18 Testing and Inspection Micro ISO Relay: Testing and Inspection Page 553 - Or information published by the manufacturer for this vehicle did not include this code For complete diagnosis of the Engine Control system, follow this link: See: Powertrain Management/Computers and Control Systems/Testing and Inspection Page 3710 8. Apply Motorcraft(R) Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 - do not let the sealant skin over. NOTE General Procedures Antenna, Radio: Service and Repair General Procedures ANTENNA GRID WIRE REPAIR 1. NOTE: A single break or any breaks which exceed 25 mm (0.98 in) (1 inch) in one grid cannot be repaired. Install a new right rear quarter-glass. Repair any inoperative grid wires using rear window defroster repair. 2. Bring the vehicle up to a room temperature of at least 16°C (60°F) or above. 3. Clean the entire grid line repair area with a non-alcohol based window cleaner and 0000 steel wool. 4. Mark the location of the grid break on the exterior of the glass. 5. Using cellulose tape, mask the area directly above the grid break. The break area should be at the center of the mask. 6. NOTE: - If the brown layer is not broken or missing, apply only the silver grid repair compound to the break. - If both the brown and silver layers of the grid are broken or missing, apply a coating of the brown touch-up paint across the break in the grid line first. Do not overlap the silver grid line with the brown paint. Several applications may be necessary to achieve a color match. - Extend the silver repair coating at least 6.35 mm (0.25 in) on both sides of the break area. - Allow at least 5 minutes of drying time between applications. Apply the repair coating to the grid break area in several smooth, continuous strokes. Apply 3 applications of the grid repair compound. 7. After 5 minutes, or after the repair area has dried completely, remove the mask. 8. CAUTION: Be careful not to damage the grid line with the razor blade. If this occurs, additional repair may be necessary. Remove any excess repair compound above or below the grid line with a razor blade. Page 6786 Suspension Strut / Shock Absorber: Service and Repair Disassembly and Assembly DISASSEMBLY AND ASSEMBLY Shock Absorber and Spring Assembly 1. Remove the shock absorber and spring assembly. 2. For reference during assembly, make an index mark on the mount, spring and shock. 3. Using a suitable spring compressor, compress the spring until the tension is released from the shock absorber. Part 1 Of 3 Part 2 Of 3 Part 3 Of 3 4. Disassemble the parts in the order indicated in the following illustration and table. 5. To assemble, reverse the disassembly procedure. Item 1: Shock Absorber-to-Up per Mount Nut Disassembly Note 1. Remove the strut and spring assembly top shaft retaining nut. ^ Position a suitable pass-through socket wrench onto the strut shaft top retaining nut. ^ Place a 10-mm six point deep well socket on top of the strut shaft. ^ Remove the strut shaft while holding the retaining nut in place. Page 2586 7. WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from the vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards. With all the restraint system diagnostic tools removed, prove out the supplemental restraint system (SRS). See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair/Prove Out Procedure 8. Check the active restraint system for correct operation. Item 3: Safety Belt Anchor Installation Note 1. NOTE: Make sure the safety belt webbing is not twisted prior to installation. Position the safety belt anchor and install the bolt. Page 6915 Page 8512 Page 6245 Brake Pressure Switch Page 3667 2. Install the special tools to the exhaust manifold. 3. Attach engine lifting equipment and raise the engine 127 mm (5 inches). Items 20, 19 and 18: Coolant Pump-to-Engine Front Cover Nuts and Bolts Installation Note Water Pump Torque Sequence 1. Install the water pump with a new gasket. ^ Tighten the nuts and bolts in the sequence shown. Page 8716 View 151-13 Service and Repair Power Steering Pump: Service and Repair Power Steering Pump Special Tool(s) CAUTION: When repairing the power steering system, care should be taken to prevent the entry of contaminants or premature failure of the power steering components can result. 1. To remove the power steering pump or the power steering fluid high pressure line, remove the vent cowl screen. 2. To remove the power steering pump or the power steering pump pulley, remove the engine accessory drive belt. 3. To remove the power steering fluid return line or the power steering fluid cooler, position the vehicle on a hoist. 4. To remove the power steering fluid return line, remove the LH front frame rail deflector shields.

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