Ford Fusion 2003 Wiring Diagram

Page 5179 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 3379 - To install, tighten to 9 Nm (80 lb-in). 4. To install, reverse the removal procedure. Page 3672 Ignition Coil: Description and Operation Coil Pack COIL PACK Horizontal Connector 6-Tower Coil Pack Series 5 6-Tower Coil Pack Page 2678 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 7105 Service and Repair Battery Cable: Service and Repair BATTERY CABLES Part 1 Page 4256 5. Remove the transaxle fill plug. 6. Fill the transmission with gear oil until level with the fill level inspection plug hole. 7. NOTE: Use a new gasket and apply sealant on the fill plug. Install the transaxle fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 8. NOTE: Use a new gasket and apply sealant on the fill level inspection plug. Install the fill level inspection plug. ^ Tighten to 35 Nm (26 ft. lbs.). Page 4214 1. Using the special tools, install a new wheel bearing into the wheel knuckle. 2. Install the wheel bearing snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. FWD vehicles 4. Install the ABS wheel speed sensor ring. 5. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 4WD vehicles 6. Install the wheel knuckle. Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 6760 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 6710 Disclaimer Page 6240 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 5292 Part 1 Page 782 P2101 Page 1409 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the catalyst monitor sensor electrical connector. Description and Operation Air Injection Pump: Description and Operation Electric Secondary Air Injection Pump For information on the electric secondary air injection pump, refer to the description of the Secondary Air Injection (AIR) Systems Page 6382 Page 7492 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 6469 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. 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). Component Locations Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 4103 Diagrams/Components/Component Location Views Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation 1. Remove the driver air bag module. 2. Remove the 4 steering wheel cover screws and the steering wheel cover. 3. Remove the 4 steering wheel brace nuts and the steering wheel brace. - To install, tighten to 9 Nm (80 lb-in) 4. Disconnect the electrical connectors. 5. Remove the 4 speed control switch screws and the speed control switches. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. Page 6509 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 4022 6. Remove the LH splash shield. 7. Remove the transaxle drain plug and drain the transmission fluid. 8. Remove the main control cover bolts, cooler bypass studs and the cover. 9. NOTE: Do not discard the gasket. It is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary. Remove the main control cover gasket. Installation Page 6193 Keyless Entry Key-Pad: Service and Repair REMOTE KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the LH front door trim panel. 2. Position the watershield aside. 3. Remove the RKE keypad retaining clip. 4. Remove the RKE keypad from the door. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Page 4011 Page 2501 Heater Hose To Block Connections Page 934 Relay Box: Locations Battery Junction Box Page 5798 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 554 P1277 Locations View 151-7 (Engine, front) Page 968 Page 908 Fog/Driving Lamp Relay: Testing and Inspection Locations View 151-4 (Engine Compartment, 2 Of 2) Application and ID Hazard Warning Flasher: Application and ID "The flasher function for this vehicle is provided by the Electronic Flasher Module and the "Generic Electronic Module." Page 105 P0158 Page 7389 View 151-25 (Liftgate) P1112 P1112 Page 7653 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 7300 C3-C4 Page 7793 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 2641 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the clutch pedal position (CPP) switch electrical connector. 3. Rotate the CPP switch clockwise and remove the CPP switch. 4. To install, reverse the removal procedure. Locations View 151-14 (Under Dash Panel, LH Side) Testing and Inspection Front Steering Knuckle: Testing and Inspection Diagnostic Routine-Vibration Page 6148 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 11. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. 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). Page 5757 Compressor Clutch Relay: Testing and Inspection Window Adjust Switch Power Window Switch: Locations Window Adjust Switch View 151-23 (Right Front Door) Page 7807 Symbols Part 4 Page 5875 Impact Sensor: Description and Operation 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 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. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have a front impact severity sensor and it is located in the front-center of the vehicle, mounted on the radiator support bracket. If the vehicle is equipped with safety canopies, there are 4 additional side impact sensors. The 4 additional sensors are located at the base of each B-pillar and mounted on the C-pillar. The LH and RH C-pillar mounted side impact sensors are interchangeable. Mounting orientation is critical for correct operation of all impact and rollover sensors. System Diagnosis P0320 Page 5782 SRS wiring, wiring harnesses and connectors 7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new components as needed. Page 7209 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 2789 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Page 4040 2. Position the clutch pressure plate on the flywheel and install the clutch pressure plate bolts. ^ Tighten to 29 Nm (21 ft. lbs.) in sequence. 3. Install the transaxle. Page 7438 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 4992 Page 1196 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 2363 18. Using the special tool, check the position of the camshafts. ^ If it is not possible to install the special tool, correct the engine timing. 19. Install the CKP sensor. ^ Do not tighten the bolts at this time. 20. Adjust the CKP sensor alignment jig. ^ Tighten the bolts to 7 Nm (62 inch lbs.). 21. Connect the CKP sensor electrical connector. 22. Remove the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt. Page 7683 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 4187 Special Tool(s) Removal and Installation 1. NOTE: If removing the intermediate shaft in order to repair a separate component, it should only be removed as an assembly with the RH front drive halfshaft. Remove the RH front drive halfshaft. 2. Remove the 2 intermediate shaft bearing retainer nuts. ^ To install, tighten to 27 Nm (20 ft. lbs.). 3. Remove the intermediate shaft. Page 2580 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Page 3137 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 3940 6. Remove the 2 nuts for the shift cable. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Loosen the bolt for the Z-bracket and rotate the Z-bracket counterclockwise to allow access to the shift cable bracket. ^ To install, tighten to 9 Nm (80 inch lbs.). 8. Disconnect the shift cable end from the manual lever. 9. Remove the shift cable from the shift cable bracket. Page 7296 Driver/Vehicle Information Display: Pinpoint Tests Compass Sensor Module C909 Instrument Cluster C220 Page 7696 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. Testing and Inspection Evaporator Core: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C Fittings Set to the evaporator or condenser 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 activates 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 gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C 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 A/C evaporator core or A/C 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 the gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then check for a loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for a vacuum loss. 9. If the A/C evaporator core or A/C condenser core leaks, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Left Front Service and Repair Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Flywheel Runout Check Flywheel: Testing and Inspection Flywheel Runout Check Flywheel Runout Check Special Tool(s) 1. Mount the special tool so that the indicator contact point rides on the straight edge which spans the clutch disc contact surface. 2. Rotate the flywheel and check the runout. If the runout exceeds the maximum allowance, install a new flywheel. Page 6287 Message Center INFO Switch C253a Message Center SET Switch C253b Test A: The Message Center Does Not Operate Correctly PINPOINT TEST A: THE MESSAGE CENTER DOES NOT OPERATE CORRECTLY Page 1138 Page 7305 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch(es). 3. To install, reverse the removal procedure. Page 6355 Accessory Delay Relay: Testing and Inspection Page 4969 Fuse Block: Application and ID Battery Junction Box Page 1717 Alignment: Description and Operation Wheel Alignment Angles 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. When the wheel tilts out at the top, the camber is positive (+). When the wheel tilts in at the top, the camber is negative (-). Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. Front caster should fall within specification when the front camber is adjusted. Toe Page 5956 Page 7926 Page 5414 Special Tool(s) Removal NOTE: If removing the wheel hub, the wheel bearing must be replaced. 1. Remove the wheel knuckle. 2. Using the special tool, press the wheel hub from the wheel bearing. Page 7145 Page 6443 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 2962 Mechanical Returnless Fuel Pump Module (FPM) Page 4999 Power Distribution Relay: Testing and Inspection Page 6783 Rear Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 2190 Inspect the crankshaft pulley for rubber protruding from the pulley (Figure 1), loose pulse wheel, or bent tabs on pulse wheel touching engine front cover. Replace crankshafl pulley with service kit for respective vehicle line. NOTE ESCAPE! MARINER HYBRID 2.3L ATK HEV ENGINE DOES REQUIRE THE SERVICE TOOLS BUT NO SERVICE KIT WAS RELEASED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062104A 2003-2007 Focus 2.3L 1.5 Hrs. PZEV 2005-2007 Focus 2.0L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A 2006-2007 Fusion/Milan 1.6 Hrs. 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A 2005-2007 Escape/Mariner 1.6 Hrs. 2005-2007 Escape Hybrid, Page 3192 Page 960 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 6802 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Diagrams Service and Repair Oil Change Reminder Lamp: Service and Repair ENGINE OIL CHANGE SOON/ENGINE OIL CHANGE NOW Displayed when the engine oil life remaining is 5% or less. When oil life left is between 5% and 0%, the ENGINE OIL CHANGE SOON message will be displayed. When oil life left reaches 0%, the ENGINE OIL CHANGE NOW message will be displayed. An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 12 months] perform the following. 1. Press the SET control to access the system check function. 2. Press and release the SET control to display "OIL CHNG XXX% HOLD SET NEW". 3. Press and hold the SET control for 2 seconds to display "OIL CHANGE SET TO 100%". Page 286 P0443 Page 1250 View 151-25 (Liftgate) Page 5522 Air Register: Service and Repair DRIVER SIDE REGISTER Removal and Installation 1. Remove the center register duct. 2. Remove the 2 driver side register nuts and the driver side register. 3. To install, reverse the removal procedure. CENTER REGISTERS Page 2875 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 1687 Wiper Switch: Testing and Inspection Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Locations View 151-7 (Engine, front) Diagrams Smart Junction Box Fuse: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 6825 Starting on either side of the vehicle, position the supplied drill guide onto the foam block so that the locating pin is set into the indentation on top of the block and the "wings" are resting on either side of the block, preventing the guide from moving side-to-side. See Figure 4. 4. WARNING: WEAR SAFETY GLASSES. CAUTION: DO NOT USE an air-powered drill for this operation. Oil spray from the tool may damage the foam block or other interior trim. CAUTION: Be sure to keep the drill motor at full speed and frequently clear the chips from the bit while drilling each hole. Bore the holes at a slow to moderate pace using light to moderate pressure on the drill. Attempting to bore the holes at a fast pace using excessive pressure on the drill, or failing to clear the chips from the bit, may cause the foam blocks to crack. NOTE: Be sure to allow the drill motor to achieve full speed before attempting to bore the hole. Drill the holes as follows: A. Holding the drilling guide securely in place, position the drill bit in either of the two (2) guide holes. See Figure 5. B. Start the drill motor and allow it to achieve full speed. Page 7626 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 706 P1651 Page 2701 View 151-8 (Engine, rear) Fuel Level Input Fuel Level Sensor: Description and Operation Fuel Level Input FUEL LEVEL INPUT NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Page 6994 11. Check to make sure the index marks on the outboard track C-channel and plastic coated slide are still in alignment. - The index marks on the outboard track C-channel and plastic coated slide must align at this step. If the index marks do not match up, repeat Steps 1 through 10. 12. Check to make sure the index marks on the inboard track C-channel and plastic coated slide are still in alignment. 13. NOTE: When assembled, a small gap between one of the gears and the drive tube may exist. Assemble the seat track motor assembly, upper support assembly and inboard track together. 1 Align the drive tube to the motor stub shaft. Tap the nose of the inboard track gear toward the seat track motor stub shaft. Positioning a block of metal or wood behind the motor gear can aid assembly. 2 While tapping the parts together, simultaneously engage the front and rear lift links to the inboard track. When the lift links are up against the inboard track, with the bushings through the hole and seated, the drive tube is fully engaged. Page 5944 View 151-19 (Center Console) Page 7808 Symbols Part 5 Page 7723 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 6413 Page 4836 Page 7524 F2 Normal Operation The illuminated entry provides interior lighting whenever the SJB receives a lamps ON/doors UNLOCK request from the RKE transmitter. The SJB provides the voltage and ground circuits for the interior/map lamps. Possible Causes - RKE transmitter - SJB Test G: The Battery Saver Does Not Deactivate After Time-Out PINPOINT TEST G: THE BATTERY SAVER DOES NOT DEACTIVATE AFTER TIME-OUT G1 Page 5620 4. NOTE: When correctly assembled, the male and female fittings should be flush. Assemble the male and female fittings together. Page 4955 Page 4698 P2195 P2195 Page 6313 B3 Normal Operation The audio unit receives a voltage signal from the smart junction box (SJB) to indicate the vehicle is in reverse on circuit 140 (BK/PK). Possible Causes - circuit 140 (BK/PK) open or short to ground - SJB - audio unit Test C: The Navigation System Does Not Operate Correctly - No Speedometer Signal PINPOINT TEST C: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - NO SPEEDOMETER SIGNAL C1-C2 Page 3977 clamp. 7. Connect the plastic retaining clip onto the frame. 8. Install the transmission fluid cooler hose onto the upper fitting of the cooler bypass valve. Install the other end of the hose to the lower radiator fitting. Pull the red clip off the constant tension clamps to activate the clamp. 9. Start the vehicle and check the transmission fluid level. ^ Fill the transaxle with clean MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON(R) V. Transmission Fluid Cooler Tubes Transmission Fluid Cooler Tubes Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. Testing and Inspection Mini ISO Relay: Testing and Inspection Page 5849 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 hardwire connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit to indicate the passenger air bag module is disabled. An exemption to this is 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 other cases, the PAD indicator is unlit when the passenger air bag module is enabled. 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 correct functional operation of the PAD indicator. The PAD indicator will lit/unlit within 1.0 to 1.5 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 enabled regardless of the size of the occupant in the front outboard passenger seat. The PAD indicator will be unlit. Passenger Air Bag PAD Indicator Status The table indicates the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant. Page 6912 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 4521 Page 1958 Brake Bleeding: Service and Repair Gravity Bleed Gravity Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RR wheel, to the LR wheel, to the RF wheel, and ending with the LF wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Loosen the bleeder screw and leave it open until clear, bubble-free brake fluid flows. 5. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the brake hydraulic system at each wheel. 7. Fill the brake master cylinder reservoir with the specified brake fluid. Page 5116 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection Ball Joint Inspection-Front Suspension Lower Arm Prior to carrying out this test, check the front wheel hub for excessive play. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Grasp the upper and lower edges of the tire. 3. Inspect for lateral movement of the steering knuckle. 1 Push and then pull on the tire and wheel assembly. 2 Inspect for movement at the ball joint. 4. Install a new front suspension lower arm if the ball joint movement exceeds 0.794 mm (0.03 inch). Page 6295 Driver/Vehicle Information Display: Service and Repair MESSAGE CENTER SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the message center switch(es). 3. To install, reverse the removal procedure. Page 4062 Page 1595 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Gearshift Lever Shifter M/T: Service and Repair Gearshift Lever Gearshift Lever Removal 1. Remove the floor console. 2. Remove the 2 gearshift cable clips. 3. Disconnect the gearshift cables from the gearshift lever. 4. Remove the 4 gearshift lever bolts. 5. Remove the gearshift lever. Installation 1. Position the gearshift lever. Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Page 3649 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Diagram Information and Instructions Courtesy 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 752 P2008 P0411 P0411 Page 245 P0353 Alignment Specifications Alignment: Specifications Alignment Specifications P1125 P1125 Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Locations Page 4120 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Remove the shift cable from the gearshift assembly. 1 Disconnect the shift cable end from the gearshift lever. 2 Remove the shift cable from the bracket. Description and Operation Air Diverter Valve: Description and Operation AIR DIVERTER VALVE Air Injection (AIR) Diverter Valve The secondary AIR diverter valve 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 system. Page 7794 92-2 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 Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the 2 fuel vapor hoses from the dust separator. 4. Slide the dust separator out of the retainer clip in the emission canister bracket. 5. To install, reverse the removal procedure. Steering - Improved Drift/Pull Diagnostics Alignment: All Technical Service Bulletins Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE 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. - Make sure the multifunction switch is in the low beam position. 4. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or ISO 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 Body Control Systems (Multifunction Electronic Control Module). - 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. See: Symptom Related Diagnostic Procedures Page 4991 Page 4823 Bleeding, Components Brake Bleeding: Service and Repair Bleeding, Components Brake System Bleeding Special Tool(s) Material Anti-Lock Brakes Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: Bleeding the hydraulic control unit (HCU) is required only when removing or installing the HCU, master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 diagnostic tool cycles and 2 manual bleed cycles. Page 3964 Transmission Cooler: Capacity Specifications Specifications Page 5910 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 7. Remove the seat cushion foam pad. 8. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 9. CAUTION: Care must be taken to prevent damage to the set cushion pan when removing the rivets. Remove the 2 rivets and the OCS ECU. 10. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 11. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. See: Occupant Classification Sensor - Service Kit 1. Bend the retaining tab back on the pressure sensor component bracket. Page 7019 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Initial Inspection and Diagnostic Overview Transmission Cooler: Initial Inspection and Diagnostic Overview Inspection and Verification When fluid leakage is found in the auxiliary fluid cooler, a new auxiliary fluid cooler should be installed. Diagrams Page 5499 Air Door Actuator / Motor: Service and Repair Temperature Blend Door Actuator TEMPERATURE BLEND DOOR ACTUATOR Removal and Installation 1. Lower the glove compartment door. 2. Turn the temperature selector to the full cold position. 3. Release the locking tab and remove the temperature blend door actuator from the blend door shaft. 4. Remove the instrument panel center finish panel. 5. Remove the temperature blend door actuator. 6. To install, reverse the removal procedure. Page 3767 Page 6282 Symptom Chart (Part 2) Page 6401 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 P0500 P0500 - P0504: Testing and Inspection P0500 P0500 (Part 1) P0500 (Part 2) Page 7508 Courtesy Lamp: Pinpoint Tests Cargo Lamp C926a Cargo Lamp C926b Page 3722 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Page 4978 Page 1313 Page 5851 4. To install, reverse the removal procedure. 5. Repower the system. Locations View 151-10 (Automatic Transmission) Testing and Inspection Mini ISO Relay: Testing and Inspection Page 5411 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. With the vehicle in NEUTRAL, position it on a hoist. 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 bearing must be installed. Page 7784 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 2092 Liftgate Ajar Switch View 151-25 (Liftgate) Description and Operation Transmission Shift Position Indicator Lamp: Description and Operation TRANSMISSION CONTROL INDICATOR LAMP (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch. Page 2149 Remove the camshafts from the engine. ^ Loosen the camshaft bearing cap bolts in the sequence shown, one turn at a time. Repeat until all the tension is released. ^ Remove the camshaft bearing caps. ^ Remove the camshafts. Installation 1. CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts, bearing caps and special tool. Tighten the bolts in the sequence shown in 3 stages: ^ Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger tight. ^ Stage 2: Tighten to 7 Nm (62 inch lbs.). ^ Stage 3: Tighten to 16 Nm (12 ft. lbs.). 2. Install the timing chain and sprockets. Page 2234 Valve Spring: Service and Repair Valve Springs Valve Springs Special Tool(s) Material Removal 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the camshafts. 3. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. WARNING: Always wear protective goggles when working with compressed air. This can prevent injury. Failure to follow these instructions can result in personal injury. CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed. Page 2663 Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 6435 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 Service and Repair Antenna Cable: Service and Repair ANTENNA LEAD-IN CABLE Removal and Installation 1. Remove the audio unit. 2. Disconnect the antenna lead-in cable from the antenna cable. 3. Release the antenna lead-in cable pin-type retainers. 4. Remove the antenna lead-in cable. 5. To install, reverse the removal procedure. Page 1701 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Page 407 P0722 Locations View 151-3 (Engine Compartment, 1 Of 2) Page 6126 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Page 3211 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 4070 2. Position the clutch pressure plate on the flywheel and install the clutch pressure plate bolts. ^ Tighten to 29 Nm (21 ft. lbs.) in sequence. 3. Install the transaxle. Page 4024 4. Install the LH splash shield. 5. Connect the vent hose to the main control cover. 6. Install the intake tube and the air cleaner cover. 7. Install the breather tube and connect the Mass Air Flow (MAF) sensor electrical connector. 8. Install the battery tray. 9. Fill the transaxle with clean automatic transmission fluid. 10. Start the engine and run through all the gears for a total of 5 minutes. Page 7759 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 2294 Engine Oil Pressure: Capacity Specifications Oil capacity .......................................................................................................................................... ........................................ 4.1 qts. + 0.4 qt. with filter Page 3975 Material Material Page 5373 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 5033 Relay Box: Application and ID Battery Junction Box Page 883 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material 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 the vehicle as-built data and calibrated. 1. Remove the hydraulic control unit (HCU). 2. Remove the 3 ABS module screws. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. Remove the ABS module. 4. To install, reverse the removal procedure. Page 5968 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 1712 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Page 6436 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 7198 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 2859 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes necessary to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. Page 6499 Symbols Part 2 Page 7688 Symbols Part 5 Page 6096 Page 7347 Page 1442 Page 836 P2273 Page 6784 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Locations A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 7660 Symbols Part 4 Page 1869 Coolant: Fluid Type Specifications Engine Coolant Type ......................................................................................................... Motorcraft Premium Gold Engine Coolant (yellow-colored) Page 3659 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Page 6972 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 7090 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the exterior mirror control switch. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 6292 D1-D3 Page 4086 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 7329 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault 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, 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 (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block will display on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays 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). Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other enhanced diagnostic tools that may have programming capabilities available. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and 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 is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic 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 installed. Manual data entry must be Carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the WDS or New Generation Star (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Page 2058 Disclaimer Page 5316 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 2279 Oil Pan: Service and Repair Oil Pan Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine oil, then install the drain plug. ^ To install, tighten to 28 Nm (21 ft. lbs.). 3. Remove the oil level indicator and tube. 4. Remove the 4 lower engine front cover bolts. 5. Remove the 4 oil pan-to-bell housing bolts. 6. Remove the 13 bolts and the oil pan. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean and inspect all mating surfaces. 2. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Apply a 2.5-mm (0.09 inch) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 rear oil pan bolts finger-tight. 3. Install the 4 oil pan-to-bell housing bolts. ^ To install, tighten to 48 Nm (35 ft. lbs.). 4. Install the 4 lower engine front cover bolts. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Install the remaining oil pan bolts. Page 7501 Courtesy 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. 89-1 Page 7023 Symbols Part 5 Page 990 Fuel Pump Relay: Testing and Inspection Page 4718 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable tool, remove the grommet. 3. Disconnect the rear wheel speed sensor wire connector. 4. Remove the rear wheel speed sensor wire from the retainer. 5. Remove the 3 rear wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 7269 Dimmer Switch: Testing and Inspection Page 7197 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. Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Page 7513 Vanity Lamps C906 (RH), C907 (LH) Test A: The Interior Lamps Are Inoperative PINPOINT TEST A: THE INTERIOR LAMPS ARE INOPERATIVE Page 7543 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 1063 Page 5696 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Compressor Connection Page 2945 Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 7639 Horn: Pinpoint Tests Clockspring C218a LH Horn C1101, RH Horn C1102 Smart Junction Box (SJB) C2280a Page 4858 Page 7201 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 4806 Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Page 1930 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ....................................................................... R134a Heated Seat Module, Passenger Side Front Transmission Range (TR) Sensor Page 5063 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 5047 Page 7667 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 Idler Pulley: Service and Repair Accessory Drive Belt Idler Pulley Removal and Installation NOTE: Vehicles that are not equipped with A/C have 2 idler pulleys. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. Loosen the bolt and remove the accessory drive belt idler pulley. ^ To install, tighten to 48 Nm (35 ft. lbs.). 5. To install, reverse the removal procedure. Page 4725 P0230 P0230 Locations Page 2311 2. Install the crankshaft rear oil seal with retainer plate and bolts. ^ To install, tighten in the sequence shown to 10 Nm (89 inch lbs.). 3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant. Clean and inspect all the oil pan and cylinder block mating surfaces. 4. NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Apply a 2.5-mm (0.09 inch) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight. 5. Install the 4 bolts. ^ To install, tighten to 10 Nm (89 inch lbs.). Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material 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 anti-lock brake system (ABS) module can be damaged if exposed to these charges. 1. Disconnect the battery. 2. Remove the air cleaner and the air cleaner outlet pipe. Page 1528 View 151-18 (Full Body, Right Rear - 2 Of 2) Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 5363 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can P0330 P0330 Page 5198 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Vehicle equipped with 3.0L engine, remove the EGR valve. Refer to Emission Control Systems. 3. NOTE: 2.3L engine shown, 3.0L engine similar. Remove the rear transaxle insulator bracket. 1 Remove the rear transaxle insulator bracket bolt. ^ To install, tighten to 90 Nm (66 ft. lbs.). 2 Remove the 2 rear transaxle insulator bracket nuts. ^ To install, tighten to 90 Nm (66 ft. lbs.). 3 Remove the rear transaxle insulator-to-bracket through-bolt. ^ To install, tighten to 90 Nm (66 ft. lbs.). Page 4906 Page 7260 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 6714 Part 2 Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. Escape Hybrid 3. Remove the steering gear. 4. If equipped with 4WD, remove the rear engine mount bracket. 1 Remove the 2 nuts. 2 Remove the bolt. To install, tighten to 90 Nm (66 lb-ft). 3 Remove the rear engine mount bracket. All vehicles except Escape Hybrid 5. Remove the 2 rear transaxle mount nuts and bolt - To install, tighten to 90 Nm (66 lb-ft). Page 2323 Flexplate, Flywheel and Crankshaft Rear Oil Seal Service and Repair Global Positioning System Module: Service and Repair AUDIO CONTROL PROTOCOL (ACP) MODULE Removal and Installation 1. Disconnect the battery. 2. Lower the glove box. 3. Remove the 2 ACP module screws. 4. Disconnect the electrical connectors and remove the ACP module. 5. To install, reverse the removal procedure. Page 6845 This program involves lowering the headliner enough to inspect the structural foam blocks which are mounted above the front corners of the headliner. Depending on the results of the inspection, dealers will either release the vehicle, or modify the structural foam blocks using a special tool and a 5/8 inch auger bit. See Figure 1. SERVICE PROCEDURE CAUTION: Failure to perform all disassembly steps as outlined increases the possibility of damaging the headliner. CAUTION: Make sure your hands are clean before performing this repair. NOTE: Although the headliner does not have to be removed to carry out the inspection or modification, a number of trim panels and components must be removed or repositioned in order to lower the front of the headliner for access. Performing all steps as outlined will position the headliner adequately for access to the repair area. NOTE: If the vehicle is equipped with any aftermarket or dealer-installed options, such as a DVD player that interferes with adequately lowering the headliner, they must be removed. DISASSEMBLY FOR INSPECTION NOTE: Perform the following steps on both sides of the vehicle. 1. Open the A-pillar assist handle bolt covers, then remove the bolts and the assist handles. 2. Remove the A-pillar trim panels. 3. At the B-pillars, remove the D-ring covers and the safety belt bolts. 4. Remove the upper B-pillar bolt covers and the bolts, then remove the B-pillar trim panels. 5. If equipped, remove the overhead console retaining screws and disconnect the electrical connector, then remove the console from the vehicle. 6. Remove the sunvisors and sunvisor clips. If equipped, disconnect the electrical connectors. 7. Open the rear seat overhead assist handle bolt covers, then remove the bolts and the assist handles. 8. Position the front and rear door weatherstrips down away from the headliner. 9. Allow the headliner to hang down loosely at the front corners. Do not pull down on the headliner or otherwise stress it, or damage may result. INSPECTION Page 7419 View 151-11 (Manual Transmission) Seat Pressure Sensor View 151-21 (Passenger Seat) Page 2764 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 4630 Brake Fluid: Service and Repair Brake Fluid Reservoir Brake Fluid Reservoir Material Removal and Installation 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. 1. Remove the reservoir cap. 2. Disconnect the brake fluid level warning switch electrical connector. 3. Using a suitable suction device, remove the brake fluid from the brake master cylinder reservoir. 4. If equipped with a manual transmission, disconnect the clutch master cylinder feed hose. Page 1182 6. Remove the front wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the front wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 4846 Page 2081 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 7324 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Page 913 Parking Lamp Relay: Testing and Inspection Page 3466 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the battery ground cable. 4. 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. Page 4707 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6513 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 6400 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). Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The message center electronic functions use both hardwired and controller area network (CAN) circuits to transmit and receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - does the module which received the input (message) control the output of the feature, or does it output a message over the CAN circuits to another module? - which module controls the output of the feature. Display Information The display modes are: information - setup - system check - warning - temporary alert - display off Using the message center, various information can be selected and reset by pressing the following buttons: SET - INFO The select display and the reset display time-out and default to the information display mode. The temporary alert display interrupts 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: compass - average fuel economy - distance to empty - instantaneous fuel economy - fuel available - units (US/metric) - language - display off Setup Displays The setup displays are timed modes and default back to the information display function. The setup display modes are: language - units (US/metric) - system check System Check The system check display is a sub-routine of the setup menu. These sub-routines 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% - charging system - door ajar - brake fluid level - check headlamps - check brake lamps - check front turn lamps - check parking lamps - fuel level - miles to empty - emission system - 4x4 OK Warning Messages Page 1084 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 4744 Part 2 Removal and Installation 1. Disconnect the battery. 2. Remove the air cleaner assembly. 3. Remove the generator B+ terminal nut. - To install, tighten to 8 Nm (71 lb-in). 4. Position the generator B+ terminal cable aside. 5. Disconnect the generator harness retainer. 6. Remove the starter solenoid terminal cover. 7. Remove the starter motor positive cable nut. - To install, tighten to 12 Nm (9 lb-ft). 8. Remove the starter solenoid wire nut. - To install, tighten to 5 Nm (44 lb-in). 9. Position the starter motor terminals aside. 10. Remove the battery ground cable bolt. - To install, tighten to 25 Nm (18 lb-ft). 11. Position the battery ground cable aside. 12. Disconnect the pin-type retainer from the left rear of the engine. 13. Disconnect the pin-type retainer from the middle of the intake runners. 14. Disconnect the pin-type retainer from the front of the engine. 15. Disconnect the clip retainer from the right front of the engine. 16. Disconnect the clip retainer from the right front of the engine. 17. Remove the body ground terminal bolt from the left fenderwell. - To install, tighten to 9 Nm (80 lb-in). 18. Open the battery junction box (BJB) cover and remove the BJB terminal nut. Front Front Door Window Glass: Service and Repair Front FRONT DOOR WINDOW GLASS Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the door trim panel bracket. 3. Position the watershield aside. 4. Remove the interior door glass weatherstrip. 5. Connect the window control switch electrical connector. 6. Connect the battery. 7. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 8. Disconnect the battery. 9. Disconnect the window control switch electrical connector. 10. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 11. Remove the front door window glass. 12. To install, reverse the removal procedure. - Cycle the front door window glass to make sure it is engaged correctly. Page 2650 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 5515 Install Center Finish Panel) 042513D Register Replace All Vents 0.4 Hr. (Includes Time To Remove And Install Center Finish Panel) DEALER CODING CONDITION BASIC PART NO. CODE 19893 41 Disclaimer Page 6425 ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable. Reprogramming of various modules may be required for some installations. Installation instructions are included with the kit. Page 4819 Page 4453 Page 3717 Spark Plug: Application and ID Spark Plug Type Spark Plug ........................................................................................................................................... .................................................................... SP448 Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Page 2940 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 7264 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 5571 Compressor Clutch Coil: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Recovery NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Page 2019 Page 4963 Page 5097 Alignment: Description and Operation Wheel Alignment Angles 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. When the wheel tilts out at the top, the camber is positive (+). When the wheel tilts in at the top, the camber is negative (-). Caster Caster is the deviation from vertical of an imaginary line drawn through the pivot points (top of strut and lower ball joint), when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. A backward tilt is positive (+) and a forward tilt is negative (-). Front caster adjustment is not a separate procedure on this vehicle. Front caster should fall within specification when the front camber is adjusted. Toe Page 2909 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 199 P0282 Page 3557 Main Relay (Computer/Fuel System): Testing and Inspection Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Service and Repair Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Press the tabs simultaneously and remove the blower motor switch. 4. To install, reverse the removal procedure. Page 6309 Audio Unit C229e Instrument Cluster C220 Test A: The Navigation System Is Inoperative PINPOINT TEST A: THE NAVIGATION SYSTEM IS INOPERATIVE Page 5689 Heater Hose To Block Connections Specifications Thermostat: Specifications If the thermostat opening voltage is greater than 0.75 volt and less than 78°C (173°F), install a new thermostat. If the thermostat opening voltage is less than 0.75 volt and greater than 78°C (173°F), the thermostat is good and a new thermostat is not required. Page 1688 Page 7028 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 4084 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 3581 Page 3822 Fluid - A/T: Testing and Inspection Transmission Fluid Level Check Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and the outside temperature is above 10°C (50°F). NOTE: Automatic transmission fluid expands when warmed. If your vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather, or while pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. The transmission fluid level should be checked at normal operating temperatures, 66°C - 77°C (150°F - 170°F), on a level surface. You can check the fluid level without driving if the outside temperature is above 10°C (50°F). When the vehicle has not been driven, and the outside temperature is above 10°C (50°F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66°C 77°C (150°F - 170°F). Fluid Level Check 1. Park the vehicle on a level surface and engage the parking brake. 2. With your foot on the brake, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 3. Place the range selector in PARK (P) and leave the engine running. 4. Remove the fluid level indicator and wipe it clean with a clean cloth. 5. Install the fluid level indicator, making sure that it is fully seated in the filler tube. 6. Remove the fluid level indicator. The fluid should be in the designated areas for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. 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 transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level Do not drive the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator, or not on the fluid level indicator and the outside temperatures are above 10°C (50°F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Page 3990 Transmission Mount: Service and Repair Lower, Rear Transaxle Support Insulator-Lower, Rear, 2.3L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the breather tube and Mass Air Flow (MAF) sensor. Page 2526 Thermostat: Testing and Inspection Thermostat A new thermostat should be installed only after the following electrical and mechanical tests have been carried out. Thermostat-Electrical Test (3.0L Only) NOTE: The electrical thermostat test is most accurate if carried out indoors at less than 37.8°C (100°F) ambient air. This test can be carried out with or without the hood open and with the engine warm or cold. 1. Check the engine coolant level. Fill as needed. 2. With the ignition OFF, attach the Rotunda 73 Digital Multimeter to the engine coolant temperature (ECT) sensor. It may be used to monitor sensor voltage values between 0-5 volts. 3. NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause incorrect diagnosis. Place the transmission in PARK (P) or NEUTRAL (N). 4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for two minutes, then record the ECT voltage. Record the ECT voltage every 60 seconds. When the ECT voltage trend changes direction or only changes slightly (0.03 volt or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart listed below. 5. If the thermostat opening voltage is greater than 0.75 volt and less than 78°C (173°F), install a new thermostat. 6. If the thermostat opening voltage is less than 0.75 volt and greater than 78°C (173°F), the thermostat is good and a new thermostat is not required. GO to Symptom Chart. See: Testing and Inspection/Symptom Related Diagnostic Procedures Thermostat-Mechanical Test 1. Remove the thermostat housing. 2. Immerse the thermostat housing and thermostat in a boiling antifreeze and water mixture. 3. See the General Specifications chart for thermostat opening temperatures. See: Specifications/General Specifications Page 4828 Page 5374 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 5687 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 3163 Mechanical Returnless Fuel Pump Module (FPM) Page 1570 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system. - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated seat). Always make sure the correct OCS service kit is installed. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing of 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 5-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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" once rezeroing of the OCS system is complete. - 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. - To identify between a production OCS system and a OCS system service kit, inspect the OCS ECU electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCS ECU. An OCS system service kit (OCS service kit) has the OCS ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 10-pin connector between the OCS ECU and the seat wiring harness. - 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor system is found only on the front passenger seat. The front passenger seat occupant classification sensor (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 bladder when the 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 pressure sensor, then electronically communicated to the OCS electronic control unit. Based on programmed limits, the OCS electronic control unit will inform the restraints control module (RCM), via a High Speed Controller Area Network (CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. 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 is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators or the owner literature. Page 2755 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Front Door Glass Top Run Window Frame: Service and Repair Front Door Glass Top Run FRONT DOOR GLASS TOP RUN Removal and Installation 1. Remove the front door window glass. 2. Remove the front door interior sail panel. - If equipped, disconnect the speaker electrical connector. 3. Remove the 2 front door glass top run bolts. - To install tighten to 6 Nm (53 lb-in). 4. Remove the front door glass top run. 5. To install, reverse the removal procedure. Page 16 P0022 Body - Door Seal Squeaking Weatherstrip: All Technical Service Bulletins Body - Door Seal Squeaking TSB 05-22-11 11/14/05 DOOR SEAL SQUEAKS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 Escape, 2005 Escape Hybrid and Mariners may exhibit squeaks from the shedlip seal for the doors. This seal runs along the top edge of the doors, above the top section of the individual door inner seals. This is most likely to be noticed at slow speeds and when the body is put into a twist. ACTION Replace the seals. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052211A 2001-2005 Escape, 2005 0.2 Hr. Escape Hybrid, 2005 Mariner: Replace The Shedlip Seal For Both Doors DEALER CODING CONDITION BASIC PART NO. CODE 7851222 41 OASIS CODES: 110000, 702000 Disclaimer Page 2223 2. NOTE: Clean and inspect the gasket. Install a new gasket, if necessary. Install the valve cover, gasket and retainers. ^ Tighten in the sequence shown to 10 Nm (89 inch lbs.). 3. Position the wiring harness and attach all of the wiring harness retainers to the valve cover studs. 4. Position the power steering tube and bracket. ^ Tighten the nut to 6 Nm (53 inch lbs.). 5. Position the accelerator control cable and brackets. ^ Tighten the nuts to 6 Nm (53 inch lbs.). 6. Attach the vacuum tube and the pin-type retainer to the intake manifold. 7. Connect the CHT sensor electrical connector. 8. Connect the fuel rail pressure and temperature sensor electrical connector. 9. Connect the CMP sensor electrical connector. 10. Install the coolant vent tube, brackets and nuts. ^ Tighten to 6 Nm (53 inch lbs.). 11. Connect the crankcase vent hose. 12. Install the ignition coil-on-plugs. Page 6279 Driver/Vehicle Information Display: Diagnostic Trouble Code Descriptions B1205-B1212 Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 4159 Seals and Gaskets: Service and Repair Drive Pinion Seal Drive Pinion Seal Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. Page 6886 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 Page 5165 Power Steering Pump: Service and Repair Power Steering Pump Pulley Power Steering Pump Pulley-2.3L Special Tool(s) Removal 1. Rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside. 2. Using the special tool, remove the power steering pump pulley. Installation 1. NOTE: Make sure the pulley is flush with the end of the power steering pump shaft. Using the special tool, install the power steering pump pulley. 2. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt. Page 2850 Spark Plug: Application and ID Spark Plug Type Spark Plug ........................................................................................................................................... .................................................................... SP448 Page 4048 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder 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, wash it immediately with water. 1. Disconnect the clutch master cylinder hose from the brake master cylinder. ^ Plug the brake master cylinder. ^ Plug the clutch master cylinder hose. 2. Remove the 2 clutch master cylinder nuts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 3. Disconnect the clutch master cylinder push rod. 4. Disconnect the clutch hydraulic fluid tube fitting. ^ Plug the clutch hydraulic fluid tube. 5. Remove the clutch master cylinder. 6. To install, reverse the removal procedure. ^ Bleed the air from the system. Page 3231 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 2739 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. P2131 P2131 Page 3467 NOTE: Carefully release the locking tabs to avoid breakage. Release the fuel rail-to-fuel supply tube quick connect coupling primary locking tab. 5. Rotate the primary locking tab to the fully opened position and squeeze the secondary locking tabs to release the locking mechanism. 6. Push the locking mechanism outward and release the fuel supply tube. 7. 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 vapor tube or retainer clip is broken or damaged, install a suitable fuel tube disconnect tool to separate the retainer clip legs. Once the retainer clip legs have separated, lift the clip out of the connector housing, lifting the stamped side of the connector body. Disconnect the remaining fuel supply tube quick connect coupling and remove the fuel supply tube. Push the connector toward the tube to release the pressure. - Press the fuel supply tube quick connect coupling button and pull the fuel supply tube to disconnect. - Remove the fuel supply tube. 8. To access fuel vapor quick connect coupling on the intake manifold, remove the LH lower splash shield. Adjustments Front Door Striker: Adjustments STRIKER ADJUSTMENT NOTE: Before adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly. 1. Loosen the door latch striker bolts. 2. Reposition the door latch striker plate from side to side or up and down as necessary. 3. Tighten the door latch striker plate bolts. 4. NOTE: The rear door is shown, the front door is similar. Check the adjustment. Repeat the procedure as necessary. Service and Repair Global Positioning System Module: Service and Repair AUDIO CONTROL PROTOCOL (ACP) MODULE Removal and Installation 1. Disconnect the battery. 2. Lower the glove box. 3. Remove the 2 ACP module screws. 4. Disconnect the electrical connectors and remove the ACP module. 5. To install, reverse the removal procedure. Locations View 151-7 (Engine, front) Page 3720 1. Inspect the spark plugs. 2. Adjust the spark plug gap as necessary. 3. Install the spark plugs. - Tighten to 12 Nm (9 lb-ft). 4. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Install the ignition coils and bolts. Tighten to 10 Nm (89 lb-in). 5. Connect the ignition coil electrical connectors. 6. Connect the battery ground cable. Page 6498 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 5919 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 6. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). 7. Connect the electrical connector(s) and wiring clips. 1 Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2 Install the 2 wiring clips on the wiring harness to the cushion pan. 3 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 4 Tie strap the unused seat wire harness pressure sensor electrical connector safely out of the way. 5 Tie strap all loose wire harnesses and electrical connectors safely out of the way. 8. Install the passenger seat into the vehicle. 9. Repower the system. Do not prove out the system at this time. 10. CAUTION: - 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. Page 1179 Diagram Information and Instructions Sunroof / Moonroof: 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 619 P1463 Locations View 151-13 (Behind Dash Panel) Page 7690 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 7664 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 4890 Page 3973 3. NOTE: Some vehicles are equipped with a cold weather bypass valve which cannot by cleaned or flushed. A new valve should be installed as part of an overhaul or prior to the installation of a remanufactured transaxle. Using compressed air, blow through the coolers until all fluid is removed. P17xx P17xx Page 1183 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Front Wheel Speed Sensor Ring-Front Removal and Installation 1. The front wheel speed sensor ring is integral to the front halfshaft and cannot be repaired separately. Page 1408 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the HO2S. To install, tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensor. To install, reverse the removal procedure. Page 5025 Relay Box: Diagrams Smart Junction Box (SJB) Page 2609 Page 5473 Wheel Bearing: Service and Repair Rear Wheel Bearing Page 7020 Symbols Part 2 Service and Repair Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 2704 Page 7024 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 4808 P1285 P1285 - P1289: Testing and Inspection P1285 P1285 (Part 1) P1285 (Part 2) A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 3624 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 6975 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 1875 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Page 6280 B1212-B1243 Page 6078 View 151-21 (Passenger Seat) Page 1991 Page 1473 Description and Operation Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. Page 4526 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable tool, remove the grommet. 3. Disconnect the rear wheel speed sensor wire connector. 4. Remove the rear wheel speed sensor wire from the retainer. 5. Remove the 3 rear wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 2989 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. Diagrams Page 4847 Multiple Junction Connector: Diagrams C312-C422 Page 98 P0152 Page 438 P0833 Page 7053 Page 1380 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Page 3325 EGR Electronic Vacuum Regulator Solenoid: Description and Operation EGR VACUUM REGULATOR (EVR) SOLENOID For information on the EVR solenoid, refer to Exhaust Gas Recirculation Systems Differential Pressure Feedback EGR (DPFE) System in this section. Page 5789 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 897 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. Service and Repair Fuel Rail: Service and Repair FUEL RAIL Exploded View 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel pressure. 2. Disconnect the battery ground cable. Page 4335 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 6607 Rear Door Exterior Handle: Service and Repair Rear Door Handles, Locks and Latches - Exploded View REAR DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 7839 Turn Signal Lamp: Diagrams Side Turn Signal Lamp Page 7806 Symbols Part 3 Page 7769 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 1965 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Page 4126 1. Install the gearshift bezel. 2. Feed the overdrive cancel switch electrical connector wire harness into the opening in the dash and install the knob. 3. CAUTION: Do not overtighten the set screw or damage to the plastic straw will occur. Install the set screw. 4. Connect the overdrive cancel switch electrical connector. 5. Install the top finish panel. Page 3999 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Service and Repair Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING CAUTION: All remote keyless entry (RKE) transmitters must be programmed at the same time. 1. The vehicle must be electronically unlocked before entering program mode (via the RKE transmitter or the door lock control switch while the driver door is open). 2. Turn the ignition switch 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 locks and then unlocks all doors. 3. Within 20 seconds, press any button on a RKE transmitter; and the doors lock and then unlock to confirm that each remote transmitter has been programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE 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 RKE transmitters are attempted to be programmed. See: Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if 1 of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of RKE transmitters have been programmed. Page 783 P2104 Page 7207 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 Application and ID Turn Signal Flasher: Application and ID "The flasher function for this vehicle is provided by the Electronic Flasher Module and the "Generic Electronic Module." Page 6105 2. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the C-pillar sheet metal. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 4. Install the C-pillar trim panel. 5. Repower the system. Page 2462 Fan Shroud: Service and Repair Cooling Fan Motor and Shroud Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the radiator grille. 3. Remove the front impact severity sensor. 4. Remove the 4 bolts and the 2 radiator brackets. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Remove the center support lower bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 6. Remove the nut and the center support. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Disconnect the cooling fan electrical connectors 8. Remove the 6 cooling fan bolts. ^ To install, tighten to 10 Nm (89 inch lbs.). 9. NOTE: Remove the LH cooling fan first and slide the RH cooling fan to the left side to remove. Remove the LH and the RH cooling fans. 10. To install, reverse the removal procedure. Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 1019 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM is restored to its original condition. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. 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 air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Page 5034 Page 6480 Symptom Chart Page 6293 D3 Continued Normal Conditions The compass sensor module receives voltage from circuit 1002 (BK/PK) and is grounded through circuit 570 (BK/WH). The compass sensor module communicates the vehicle direction to the instrument cluster, which is displayed in the message center. The compass sensor module uses circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster. Possible Causes - circuit 1002 (BK/PK) open - circuit 570 (BK/WH) open - circuit 702 (WH/BK) open or short to ground - circuit 703 (WH/OG) open or short to ground - compass sensor module Test E: The Compass Is Inaccurate PINPOINT TEST E: THE COMPASS IS INACCURATE Page 7994 Page 1963 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 4270 2. Connect the select cable. 3. Connect the gearshift cable. 4. CAUTION: Make sure the clips are set completely within the cable adapter groove and fully seated. Install the 2 gearshift cable clips. 5. Install the 4 gearshift lever bolts. ^ Tighten to 20 Nm (15 ft. lbs.). 6. Adjust the gearshift cables. 7. Install the floor console. Master Window/Door Lock/Unlock Switch Page 134 P0193 Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Parking Aid Sensor, Outer Left View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6081 Page 3969 Transmission Cooler: Symptom Related Diagnostic Procedures Symptom Chart Page 6251 Page 6312 A5 Normal Operation The audio unit receives voltage on circuits 137 (YE/BK), 1786 (BN/PK) and 956 (OG/LG) and is grounded by circuit 694 (BK/LG). Possible Causes - circuit 137 (YE/BK) open - circuit 956 (OG/LG) open - circuit 694 (BK/LG) open - audio unit Test B: The Navigation System Does Not Operate Correctly - No Reverse Tracking PINPOINT TEST B: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - NO REVERSE TRACKING B1-B2 P0280 P0280 Service and Repair Differential Cover: Service and Repair Differential Housing Cover Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Drain the differential fluid into a suitable drain pan. Remove the 10 bolts and the rear differential cover. ^ Drain the differential fluid from the housing. Installation 1. CAUTION: Make sure the machined surfaces on the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surfaces of the differential housing and the differential housing cover. 2. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has correctly cured. Apply a new continuous bead of clear silicone rubber as shown in the illustration. 3. Install the differential housing cover and the 10 bolts. ^ Tighten to 23 Nm (17 ft. lbs.). 4. Fill the rear axle with 1.4 liters (2.95 pints) of rear axle lubricant, 3 - 5 mm (0.118 - 0.196 inch) below the bottom of the filler hole and install the filler plug. ^ Tighten to 27 Nm (20 ft. lbs.). Page 7613 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 7828 Z1-Z2 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits 52 (YE) and 64 (DG) supply voltage to the trailer tow LH and RH stop/turn lamps respectively. Circuit 962 (BN/WH) supplies voltage to the trailer tow parking lamps. Possible Causes - circuit 64 (DG) short to voltage - circuit 52 (YE) short to voltage - circuit 962 (BN/WH) short to voltage - SJB Page 555 P1278 Page 834 P2271 Locations View 151-10 (Automatic Transmission) Page 52 P0114 Page 88 P0144 Page 2285 Oil Pressure Sender: Service and Repair Oil Pressure Sender Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Disconnect the oil pressure sender electrical connector. 4. Remove the oil pressure sender. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. To install, reverse the removal procedure. ^ Apply pipe sealant with Teflon to the oil pressure sender threads. Page 1139 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the exterior mirror control switch. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 7925 Page 7817 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 5340 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Page 1852 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Material Door Lock Unit Power Door Lock Actuator: Diagrams Door Lock Unit Page 3831 Special Tool Seal Removal Transmission Filter Page 1403 Page 44 P0105 - P0109: Testing and Inspection P0107 P0107 (Part 1) P0107 (Part 2) Page 5915 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 electronic control unit (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 OEM OCS, refer to the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate Page 991 Page 7488 Symbols Part 3 Page 4867 P0135 P0135 Diagrams Page 2988 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 Fuel Rail Pressure/Temperature Sensor Page 1130 Page 6247 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Page 5862 3. NOTE: - Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column. - The clockspring is shown from the back for clarity. Align the clockspring for installation. Align the large slot to the large tab in the clockspring. - Align the small slot to the small tab in the clockspring. 4. Install the 3 clockspring screws. 5. For vehicles reusing a clockspring that was removed, remove the tape. For vehicles installing a new clockspring, remove the retaining pin. 6. Install the lower steering column shroud and the 3 screws. 7. Position the steering column completely downward and lock in place. 8. Install the upper steering column shroud and engage the retaining tabs. 9. Install the steering wheel. 10. Repower the system. Page 4281 Shifter M/T: Service and Repair Gearshift Cables Gearshift Cables Removal 1. Remove the floor console. Locations Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 2931 Connector Views Fuse Block: Connector Views Page 4595 Brake Drum: Service and Repair Brake Drum Special Tool(s) Removal CAUTION: To reduce the possibility of uneven braking, always install new rear brake shoes at both ends of an axle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result. NOTE: If the brake drum is seized to the wheel hub pilot diameter, tap the center of the brake drum between the wheel studs. If the brake drum binds on the brake shoes, retract the brake shoes. 1. Move the brake shoe adjuster actuator lever away from the adjuster. 2. Rotate the brake shoe adjuster screw upward to retract the brake shoes. 3. Remove the brake drum. Installation 1. Using the special tool, measure the inside diameter of the brake drum. ^ Install a new brake drum if the inside diameter exceeds the specification stamped on the outside face of the brake drum. 2. Adjust the rear brakes, refer to Brake Shoe Adjustment. 3. Position the brake drum on the vehicle. Page 4647 4. If equipped with a manual transmission, disconnect the clutch master cylinder feed. ^ Plug the clutch master cylinder feed hose. 5. If installing a new brake master cylinder, remove the brake fluid reservoir. 6. Disconnect the 2 brake line fitting and plug the brake lines and the brake master cylinder ports. ^ To install, tighten to 15 Nm (11 ft. lbs.). 7. NOTE: Install new master cylinder nuts. Remove and discard the 2 master cylinder nuts. ^ To install, tighten to 25 Nm (18 ft. lbs.). 8. Remove the brake master cylinder assembly. 9. To install, reverse the removal procedure. ^ Bleed the master cylinder. ^ If equipped with a manual transmission, bleed the clutch master cylinder. Page 2192 Harmonic Balancer - Crankshaft Pulley: Specifications Tighten the Crankshaft pulley bolt in 2 stages: Stage 1: Tighten to .............................................................................................................................. .................................. 100 Nm (74 ft. lbs.) . Stage 2: Tighten an additional 90 degrees (1/4 turn). Locations Page 7151 Cruise Control Servo: Service and Repair SPEED CONTROL ACTUATOR Removal 1. Press the locking tab and rotate the speed control cable cap to remove. Page 6991 1. NOTE: This step is critical in getting the inboard and outboard tracks in alignment. Otherwise, when installing the seat in vehicle, the holes in the track mounting ears will not align to the holes in the floor pan and the seat track may prematurely fail due to binding. Position the new and old seat track motor assembly side by side. Position the new seat track motor assembly stub shaft flat spots (splines) in the same position as the old seat track motor assembly flat spots. If necessary, apply power and ground to the new seat track motor electrical connector as shown during removal to obtain the same position. 2. NOTE: The front and rear height adjustment gears do not have to mesh with the seat track motor assembly gears at the same teeth as when disassembled. Install the seat track motor assembly to the upper support assembly. 1 NOTE: Make sure the motor is positioned right side up. Install the seat track motor assembly pivots through the front and rear height adjustment gear brackets. Apply multi-purpose grease to the motor pivots. 2 Mesh the seat track motor assembly gears to the front and rear height adjustment gears. There should not be a gap between the upper support assembly gears and the seat track motor assembly housing. Page 4405 Seat Pressure Sensor Diagram Information and Instructions Information Bus: 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 Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................. 1.25 - 1.35mm (0.049 - 0.053 in.) Spark Plug Tightening Torque ............................................................................................................. ........................................................ 12 Nm (9 lb.ft.) Windshield Washer Pump and Reservoir - Exploded View Windshield Washer Reservoir: Service and Repair Windshield Washer Pump and Reservoir Exploded View WIPER AND WASHER SYSTEM - EXPLODED VIEW, WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. For additional information, refer to the procedures. Page 7979 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 5609 Control Assembly: Service and Repair Temperature Control Switch TEMPERATURE CONTROL SWITCH Removal and Installation 1. NOTE: Place the temperature selector switch in the full cold position before disengaging the temperature blend door actuator. Remove the instrument panel center finish panel. 2. Remove the temperature selector switch knob. 3. Remove the temperature selector switch screw. 4. Press the tab and rotate the temperature selector switch counterclockwise. - Remove the temperature selector switch. Page 4849 Page 3306 1. Remove the fuel tank. 2. Squeeze the coupling opposite the release tabs and pull to release the fuel vapor tube quick connect coupling from the fuel vapor control tube assembly valve fitting. 3. Squeeze the coupling opposite of the release tabs and pull to release the fuel vapor control assembly valve tube quick connect coupling from the evaporative emissions (EVAP) canister vent solenoid. 4. 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. Using the special tool, disconnect the fuel vapor control tube assembly valve quick connect coupling from the fuel filter vapor tube. Remove the fuel vapor control tube assembly valve. Installation Page 7072 View 151-22 (Left Front Door) Locations View 151-8 (Engine, rear) Fuel Pump Module Fuel Pressure Regulator: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 4778 View 151-4 (Engine Compartment, 2 Of 2) Passenger Air Bag Module Page 3528 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the 3 screws, the pin-type retainer and the upper and lower snow shield. - To install, tighten to 10 Nm (89 lb-in). 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the 2 bolts and the IAC valve. - To install, tighten to 4 Nm (35 lb-in). - Inspect the gasket and install new as necessary. 5. To install, reverse the removal procedure. Safety Belt Buckle and Pretensioner Seat Belt Tensioner: Service and Repair Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER Torx Bit, Safety Belt Bolt Special Tool(s) Removal and Installation WARNING: - All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 Page 4993 Page 2443 Radiator Cooling Fan Motor: Testing and Inspection Cooling Fan Motor and Shroud 1. Inspect the fan blade and shroud for any foreign materials. Clear the obstruction and continue the test procedure. 2. Rotate the fan to see if any contact between the shroud and blade exists. If contact is observed, install a new fan shroud assembly. 3. Rotate the fan by hand. The fan should rotate freely (no resistance should be felt, the fan will free-wheel with minimum effort). If any resistance is present, install a new fan assembly. Page 6973 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 Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE PIPE Page 3294 connector retaining clip area before separating the tube. Disconnect the fuel vapor tube quick connect coupling. Push the connector toward the tube to release pressure. - Press the fuel vapor tube quick connect coupling button and pull the fuel vapor tube to disconnect. 4. 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. Disconnect the fuel vapor tube quick connect coupling. 1 Press the fuel vapor tube quick connect coupling lock tabs. 2 Disconnect the fuel vapor tube quick connect coupling. 5. Depress the tab and remove the EVAP canister purge valve from the bracket. Installation 1. NOTE: Make sure that the EVAP canister purge valve tab snaps and locks into place on the bracket. Install the EVAP canister purge valve on the bracket. 2. NOTE: - Make sure the collar on the fuel vapor tube is inserted fully into the quick connect coupling before the locking tab is locked. - Apply clean engine oil to the end of the tube before inserting the tube into the connector. Install the fuel vapor tube quick connect coupling. 1 Connect the quick connect coupling to the tube. 2 Press the quick connect coupling locking tab into position. Pull on the fitting to make sure it is fully engaged. A/T - Shifter Release Button Cap Falls Off Shifter CVT: Customer Interest A/T - Shifter Release Button Cap Falls Off TSB 05-4-5 03/07/05 SHIFTER RELEASE BUTTON CAP FALLS OFF FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Mariner and Escape Hybrid vehicles may exhibit a loose gear selector button cap. The button cap may fall off, and will not stay in place when re-seated. ACTION Replace the gear selector button cap only, it is not necessary to replace the entire gear selector lever. For additional information, see the latest Escape/Mariner Workshop Manual CD, Section 307-05 Selector Lever Button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050405A 2005 Escape/Escape 0.2 Hr. Hybrid/Mariner: Replace Shifter Button DEALER CODING CONDITION BASIC PART NO. CODE 7C488 33 Disclaimer Page 2355 Removal 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt and idler pulleys. 3. Remove the engine mount. 4. Remove the valve cover. 5. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. ^ The hole in the crankshaft pulley should be in the 6 o'clock position. 6. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. Page 7802 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 1591 View 151-21 (Passenger Seat) Locations View 151-11 (Manual Transmission) Diagrams P0060 P0060 Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the 8 cowl panel grille pin-type retainers. 4. Remove the 8 cowl panel grille caps and screws. 5. Remove the LH cowl panel grille. 6. Remove the RH cowl panel grille. 7. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Page 1029 Page 6376 Page 2677 Mechanical Returnless Fuel Pump Module (FPM) Page 1215 Page 4716 6. Remove the front wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the front wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 1131 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: LH side shown, RH side similar. 1. Remove the front door trim panel. 2. On Mariner vehicles, remove the 3 screws and the front door trim panel arm rest. 3. Release the bezel retaining clip from the door trim panel. 4. Release the locking clips and remove the window control switch. 5. To install, reverse the removal procedure. Page 680 P1568 Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Diagrams Page 4390 Fluid - Transfer Case: Service and Repair Manual Transaxle Transfer Case Draining and Filling-Manual Transaxle Material CAUTION: New transfer case lubricant must be installed any time the transfer case has been submerged in water. NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected. To drain the transfer case fluid, the transfer case must be removed from the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground. Remove the fill plug and fill the transfer case with rear axle lubricant. 3. Install the fill plug and gasket. ^ Tighten to 49 Nm (36 ft. lbs.). Page 7295 Symptom Chart (Part 5) Service and Repair Positive Crankcase Ventilation Valve: Service and Repair POSITIVE CRANKCASE VENTILATION (PCV) VALVE Exploded View Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Disengage the positive crankcase ventilation (PCV) valve cap from the two tabs and remove the PCV valve. 4. To install, reverse the removal procedure. Page 3006 E1-E2 Normal Operation The parking aid module communicates with the diagnostic tool through the ISO 9141 communication network circuit 70 (LB/WH). If circuit 70 (LB/WH) becomes open or shorted to ground, communication to that module is not possible. Check circuit 70 (LB/WH) between the parking aid module C4014 and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open in circuit 70 (LB/WH), damage to the DLC C251, damage to the parking aid module C4014, or a problem in an in-line connector. Possible Causes - ISO 9141 communication network circuit 70 (LB/WH) open - DLC C251 - C4014 - parking aid module Test F: No International Standards Organization (ISO) 9141 Communication Network Communication PINPOINT TEST F: NO INTERNATIONAL STANDARDS ORGANIZATION (ISO) 9141 COMMUNICATION NETWORK COMMUNICATION Page 1472 Page 3623 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Page 976 Main Relay (Computer/Fuel System): Testing and Inspection Diagrams Page 5570 Page 5354 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Parking Aid Sensor, Outer Left Page 1615 Power Steering Pressure Switch: Diagrams Specifications Connecting Rod: Specifications Connecting Rod Crank bore diameter ................................................................................................................................................. 53.025-53.045 mm (2.087-2.088 in.) Pin bore diameter ..................................................................................................................................................... 20.965-20.985 mm (0.825-0.826 in.) Length (center-to-center) .......................................................... ........................................................................................................ 154.8 mm (6.094 in.) Side clearance ............................................................................................................................................. ..................... 1.95-3.05 mm (0.076-0.120 in.) Axial clearance ............................................................ .................................................................................................... 0.14-0.36 mm (0.005-0.014 in.) Connecting rod journal diameter .............................................................................................................................. 49.980-50.000 mm (1.967-1.968 in.) Locations View 151-13 (Behind Dash Panel) Page 491 P1151 Page 7278 Page 3168 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Page 3150 Fuel Level Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Diagrams Front Crankshaft Seal: Diagrams Lower End Components-Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Brakes - Rear Disc Brake Grinding/Rubbing/Thumping Brake Pad: All Technical Service Bulletins Brakes - Rear Disc Brake Grinding/Rubbing/Thumping TSB 05-13-8 07/11/05 REAR DISC BRAKE GRIND, RUBBING OR THUMP NOISE FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner This article supersedes TSB 05-9-25 to increase the labor operation time. ISSUE Some 2005 vehicles may exhibit a rear disc brake grind, rubbing or thump. The noise may be more noticeable during cool or wet conditions, and usually occurs during initial brake application after setting over night. This may be due to the composition of the brake lining material. ACTION Machine the rear rotors and install new rear disc brake linings made of revised material. Refer to Section 206-04 of the Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051308A 2005 Escape, Manner, 1.5 Hrs. Escape Hybrid: Machine The Rear Brake Rotors And Install New Rear Disc Brake Linings (Do Not Use With 2001B, 2001B1, 2001B3P, 2001B3PT) DEALER CODING CONDITION BASIC PART NO. CODE 2200 D4 Disclaimer Page 5799 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Locations View 151-12 (Dash Panel) Page 1833 Removal and Installation 1. Recover the refrigerant. 2. Loosen the nut and disconnect the evaporator inlet line fitting. - Remove and discard the O-ring. - To install, tighten to 10 Nm (89 lb-in). 3. Disconnect the orifice evaporator inlet line spring lock coupling and remove the orifice evaporator inlet line. 4. NOTE: New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Charge and leak test the refrigerant system. Page 4547 5. CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the piston. NOTE: Inspect the brake caliper piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new caliper must be installed. Remove the caliper piston. 1. Place a block of wood between the brake caliper piston and the brake caliper housing. 2. Apply compressed air through the caliper jounce hose port to remove the piston. 6. Remove the dust boot. 7. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. Remove the piston seal from the brake caliper bore. 8. To assemble, reverse the disassembly procedure. ^ Lubricate the piston seal with clean brake fluid. Page 5723 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 the 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 1880 Adding Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. The type of fluid that should be used is found on the fluid level indicator, on the handle, in the owner's manual, and in the Specifications. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill the fluid. 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. 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 transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Page 517 P1238 Page 5162 Removal CAUTION: While 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. Rotate the tensioner clockwise and remove the belt from the power steering pump pulley. Refer to Drive Belts, Mounts, Brackets and Accessories. Page 5041 Page 5698 Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the A/C refrigerant. 3. Remove the 2 compressor manifold and tube assembly bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the spring lock coupling from the suction accumulator. 5. Remove the front bumper cover. 6. Disconnect the condenser core peanut fitting. - Remove the condenser core peanut fitting nut. To install, tighten to 8 Nm (71 lb-in). 7. Remove the RH splash shield. 8. If equipped, disconnect the engine block heater. 9. Disconnect the A/C compressor electrical connector. 10. Remove the manifold and tube assembly bolt. - To install, tighten to 20 Nm (15 lb-ft). Diagrams Automatic Transaxle Fluid - Transfer Case: Service and Repair Automatic Transaxle Transfer Case Draining and Filling-Automatic Transaxle Material CAUTION: New transfer case lubricant must be installed any time the transfer case has been submerged in water. NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected or a repair is necessary. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the drain plug and drain the transfer case. 3. Apply silicone sealant to the drain plug threads and install the drain plug. ^ Tighten to 10 Nm (89 inch lbs.). 4. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground. Remove the fill plug and fill the transfer case with rear axle lubricant. 5. Apply silicone sealant to the fill plug and install the plug. ^ Tighten to 16 Nm (12 ft. lbs.). Page 4520 Forward Crash Sensor View 151-3 (Engine Compartment, 1 Of 2) Page 5539 Specifications Compressor Clutch: Specifications Item....................................................................................................................................................... ..............................................................Specification Magnetic clutch Air gap between pulley and hub........................................................................................................... ....................................0.35-0.75 mm (0.014-0.029 in) Page 3654 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Page 7969 21. Position the 2 A-pillar passenger assist handles and install the 4 A-pillar passenger assist handle bolts and 4 covers. - Tighten to 5 Nm (44 lb-in). Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 7227 Symbols Part 2 Page 6010 Page 1144 Power Seat Switch: Testing and Inspection Page 510 P1234 Page 2329 CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the camshafts. 3. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. WARNING: Always wear protective goggles when working with compressed air. This can prevent injury. Failure to follow these instructions can result in personal injury. CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect the compressed air from the cylinder until the valve spring, valve spring retainer and valve collet is installed. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply. 5. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. ^ Using the special tools, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. ^ Remove the valve spring retainer and the valve spring. 6. Using the special tools, remove and discard the valve seal. Installation Connector Views Engine Control Module: Connector Views Page 6831 4. Push the headliner back into its proper position. Clamp in place using a flat piece of metal or wood to keep the headliner flush against the underside of the roof panel (Figure 3). Allow the adhesive to cure for 45 minutes. 5. Remove clamps and reinstall the perimeter seal. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050803A 2004-2005 Escape/Escape 0.3 Hr. Hybrid/Mariner Adhere The Headliner To The Underside Of The Roof Panel (Do Not Use With 51916A, 51916B, 51916BXH) DEALER CODING CONDITION BASIC PART NO. CODE 7851944 34 Disclaimer P1115 P1115 P1506 P1506 Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Page 5821 Part 2 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. - To reduce the risk of personal injury from an accidental deployment, always carry or place a live safety canopy module with the safety canopy and tear seam pointed away from your body. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Anytime the safety canopy has deployed, the headliner, and all A-, B- and C-pillar upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment. - Vehicles equipped with safety canopy modules require a specific headliner. When installing a new headliner on a vehicle equipped with safety canopy modules, make sure a headliner for safety canopy modules is being used. The word "AIRBAG" will appear on the headliner where it meets each B-pillar trim panel. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Before installing a safety canopy module, inspect the roof line for any damage. If necessary, the sheet metal must be reworked to its original condition and structural integrity. All damaged fasteners must be replaced and any foreign objects removed. Failure to do so may result in personal injury in the event of a safety canopy deployment. - Inspect the safety canopy before installation. If the safety canopy is damaged or the cover has separated and the canopy material has been exposed, a new safety canopy module must be installed. Do not attempt to repair the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - To reduce the risk of injury, do not obstruct or place objects in the deployment path of the safety canopy module. Failure to follow these instructions can result in personal injury in the event of a safety canopy module deployment. - Never put any type of fastener or tie strap around any part of the safety canopy module or interior trim panel. This will prevent the safety canopy module from deploying correctly. Failure to do so can result in personal injury in the event of a safety canopy module deployment. - Never probe the electrical connector on a safety canopy module. Doing so can result in safety canopy deployment. - To reduce the risk of personal injury, do not use any memory saver devices. - The safety canopy must be installed in the vehicle using new torque-prevailing type J-nuts (W520822, 5 per side). Use of this J-nut is mandatory so as to reduce the risk of loss of fastener effectiveness. Failure to follow these instructions may result in personal injury in the event of a safety canopy deployment. NOTE: - There are 2 different safety canopy modules, one for vehicles with a moonroof and one for vehicles without a moonroof. They are not interchangeable. If installing a new safety canopy module, the correct safety canopy module MUST be installed for the vehicle application. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side safety canopy module shown, LH side similar. 1. Depower the system. 2. Remove the headliner. 3. If reusing the same safety canopy module, separate the tether from the pin-type retainer. If a new safety canopy module is being installed, detach the tether with the pin-type retainer. 4. NOTE: If equipped with a moonroof and or rear window wiper assembly, note position and routing of the moonroof front drain hose and/or rear window washer solvent hose for installation purposes. Remove the A-pillar tether bolt. 5. Remove the 2 safety canopy module bolts located near the top of the A and B-pillars. Page 4189 4. Slide the inner CV boot off the inner CV joint housing. 5. Separate the tripod joint from the inner CV joint housing. 6. If installing the original tripod joint, mark the tripod joint and the front drive halfshaft to be sure of correct installation. 7. Remove the snap ring. Page 5455 Disclaimer System Diagnosis P1443 Page 2872 Air Flow Meter/Sensor: Diagrams Alignment Specifications Alignment: Specifications Alignment Specifications Specifications Fluid Pan: Specifications Main Control Cover Tighten bolts and studs in the indicated sequence .................................................................................................................................... 13 Nm (10 ft. lbs.) Page 5032 Page 7691 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 Block Heater: Specifications Block heater (2.3L) .............................................................................................................................. ..................................................... 21 Nm (15 ft. lbs.) Block heater (3.0L) ........................................... ........................................................................................................................................ 21 Nm (15 ft. lbs.) Page 3157 Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Page 5722 Disconnect the high-pressure and low-pressure valves and remove the injector loop kit from the vehicle. Fuel Level Input Fuel Level Sensor: Description and Operation Fuel Level Input FUEL LEVEL INPUT NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Recall - Interior Impact Non-Compliance Technical Service Bulletin # 06C12 Date: 060512 Attachment I - Administrative Information Page 7968 8. Apply foam dam to the bottom of the windshield glass. 9. Cut the urethane adhesive applicator tip to specification. 10. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. Apply a bead of urethane adhesive to the sides and top of the windshield glass. 11. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. Apply a bead of urethane adhesive to the bottom of the windshield glass outside the foam dam. 12. Install the windshield glass, aligning it to the marks previously made. 13. NOTE: The urethane adhesive must cure for a minimum of 1 hour before testing for air and water leaks. After the urethane adhesive has cured, check for water leaks and add urethane adhesive where needed. 14. If necessary, remove excess urethane adhesive from the exterior surface of the windshield glass. 15. Install the cowl panel grille. 16. Reposition the front portion of the headliner. 17. Position the 2 sun visors and 2 clips and install the 4 sun visor screws and 2 clip screws. 18. Install the interior rear view mirror. 19. Position the overhead console and install the 2 overhead console screws. - If equipped, connect the electrical connector. 20. Install the 2 windshield side garnish mouldings. Page 5090 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Page 3495 Fuel Gauge Sender: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 2754 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 5909 and ECU) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electronic control unit (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 the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connectors and wiring clips. 1 Disconnect the OCS ECU electrical connector. 2 Disconnect the pressure sensor electrical connector. 3 Release the 2 wiring clips on the wiring harness from the cushion pan. 4 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill-Without Torque Converter Drain Plug Material Draining 1. With the vehicle in NEUTRAL position it on a hoist. 2. NOTE: If an internal problem is suspected, drain the fluid through a paper filter. A small amount of metal or friction particles may be found from normal wear. If an excessive amount of metal or friction material is present the transaxle will need to be overhauled. Remove the transaxle drain plug. Refill 1. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). 2. Fill the transaxle with clean automatic transmission fluid. 3. Start the engine and run through all the gears and check fluid level. Page 187 P0273 Page 6144 a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connector(s) and wiring clips. 1 Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2 Release the 2 wiring clips on the wiring harness from the cushion pan. 3 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Specifications Oil Pan: Specifications Oil pan bolts Install the 2 rear oil pan bolts finger-tight. Install the remaining oil pan bolts. To install, tighten in the sequence shown to 25 Nm (18 ft. lbs.). Page 2200 Using the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt, check the position of the crankshaft pulley. ^ If it is not possible to install the bolt, correct the engine timing. 11. Using the special tool, check the position of the camshafts. ^ If it is not possible to install the special tool, correct the engine timing. 12. Remove the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt. 13. Install the engine plug bolt. ^ To install, tighten to 20 Nm (15 ft. lbs.). 14. Install the accessory drive belt. 15. Install the valve cover. Page 7918 Power Window Switch: Diagrams Window Adjust Switch Page 4943 Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Page 3004 C1-C2 Normal Operation The ABS module communicates with the diagnostic tool through the high speed CAN communications network, circuits 1908 (WH) and 1909 (BK). If one of the bus wires becomes shorted to ground or voltage, communication can continue at a reduced level. Check circuits 1908 (WH) and 1909 (BK) between the ABS module C155 and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the high speed CAN circuits, damage to the DLC C251, damage to the ABS module C155, or a problem in an in-line connector. Possible Causes - high speed CAN circuits 1908 (WH) and 1909 (BK) open - DLC C251 - C155 - ABS module Test D: The Four-Wheel Drive (4WD) Control Module Does Not Respond to The Diagnostic Tool PINPOINT TEST D: THE FOUR-WHEEL DRIVE (4WD) CONTROL MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Page 6483 Y2-Y4 Page 5628 Evaporator Core: Service and Repair EVAPORATOR CORE Removal and Installation NOTE: - Installation of a new suction accumulator is not necessary when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C component or damage to the suction accumulator. - If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. - The evaporator core and evaporator housing must be installed as a complete unit. 1. Remove the A/C evaporator core housing. 2. Transfer, the components from the old evaporator core housing to the new evaporator core housing. 3. To install, reverse the removal procedure. - Lubricate the new A/C evaporator core with the correct amount of PAG Compressor Oil YN-12-C or equivalent meeting Ford specification WSH-M1C231-B. P0350 P0350 Page 2502 Heater Hose To Oil Cooler Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. If removing the heater core hoses, remove the heater hose tie. 4. Release the clamps and remove the necessary heater hose(s). 5. To install, reverse the removal procedure. NOTE: Lubricate the coolant hoses with plain water only if needed. Fill the engine cooling system. Page 2645 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 5064 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 4606 To assemble, reverse the disassembly procedure. Page 5937 Service and Repair Body Control Module: Service and Repair SMART JUNCTION BOX (SJB) Removal and Installation 1. CAUTION: Prior to removal of the SJB, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery. 2. Remove the floor console SJB cover. 3. Remove the transmission selector lever bezel from the floor console finish panel. 4. Apply the parking brake. 5. Remove the parking brake lever boot from the floor console finish panel. 6. Remove the floor console finish panel. Parking Aid Sensor, Outer Left Page 545 P1271 Page 695 P1636 Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. Page 6206 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 7288 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 concern is not visually evident, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or ISO circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for the instrument cluster, refer to Instrument Cluster. - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the instrument cluster. 7. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Index to continue diagnosis. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnosis. See: Symptom Related Diagnostic Procedures Page 3252 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 5912 11. Connect the electrical connectors and wiring clips. 1 Connect the OCS ECU electrical connector. 2 Connect the pressure sensor electrical connector. 3 Install the 2 wiring clips on the wiring harness to the cushion pan. 4 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 12. Install the passenger seat into the vehicle. 13. Repower the system. Do not prove out the system at this time. 14. CAUTION: - 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Service and Repair Valve: Service and Repair Valve Clearance Check 1. Remove the valve cover. 2. CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in these locations. Page 5973 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 7574 Fog/Driving Lamp Relay: Testing and Inspection Page 6458 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 7909 Service and Repair Shift Cable: Service and Repair Transmission Selector Lever Cable Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector level in the (D) position. Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 5152 Disclaimer Page 4194 Axle Shaft Assembly: Service and Repair Rear Drive Halfshaft Removal and Installation Halfshaft Special Tool(s) Wheel Speed Sensor-Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front Wheel Speed Sensor-Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The harness connector is located in the engine compartment. Disconnect the electrical connector. 3. Using a suitable tool, remove the grommet. 4. Remove the front wheel speed sensor wire from the retainer. 5. Remove the 2 front wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). P1900 P1900 Page 7965 Windshield: Service and Repair Removal and Installation WINDSHIELD GLASS Special Tool(s) Special Tool(s) Page 1184 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Rear Wheel Speed Sensor - Rear Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Using a suitable tool, remove the grommet. 3. Disconnect the rear wheel speed sensor wire connector. 4. Remove the rear wheel speed sensor wire from the retainer. 5. Remove the 3 rear wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 6. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the rear wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. Remove the rear wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 3307 1. CAUTION: Make sure the vapor 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 the tube into the connector. Install the fuel vapor control tube assembly valve and install the fuel vapor tube quick connect coupling onto the fuel filter vapor tube. Pull on the fitting to make sure it is fully engaged. 2. Press the fuel vapor control tube assembly valve quick connect coupling onto the EVAP canister fitting until it locks in place and is fully seated. - Pull on the coupling to make sure it is fully engaged. 3. Press the fuel vapor tube quick connect coupling onto the fuel vapor control tube assembly valve fitting until it locks in place and is fully seated. - Pull on the fitting to make sure it is fully engaged. 4. Install the fuel tank. 5. Carry out a leak test. See: Testing and Inspection/Evaporative Emission System Leak Test 6. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Page 5294 6. Remove the power steering hose bracket bolt. - To install, tighten to 10 Nm (89 lb-in). 7. Using the special tool, support the engine. 8. Remove the bolts and the lateral support crossmember. - To install, tighten to 115 Nm (85 lb-ft). 9. Remove the splash shield bolt. 10. Remove the front insulator bolt. - To install, tighten to 115 Nm (85 lb-ft). 11. Remove the 2 engine support crossmember bolts. - To install, tighten to 90 Nm (66 lb-ft). 12. Remove the nut and the engine support crossmember. - To install, tighten to 175 Nm (129 lb-ft). 13. Remove the 2 lower control arm ball joint pinch bolt and nuts. - To install, tighten to 70 Nm (52 lb-ft). 14. Remove the 2 nuts and disconnect the 2 stabilizer bar links. - To install, tighten to 47 Nm (35 lb-ft). 15. Remove the 2 steering gear bolts. - To install, tighten to 115 Nm (85 lb-ft). 16. Position the steering gear out of the subframe mounts. 17. Remove the exhaust flexible pipe (2.3L) or the dual converter Y-pipe (3.0L). 18. If equipped with 4WD, remove the driveshaft. 19. NOTE: The engine must be lowered to allow the front subframe to clear the transaxle companion flange. If equipped with 4WD, use the special tool to lower the rear of the engine approximately 150 mm (5.9 in). 20. NOTE: - Do not allow the front subframe rear bolts to come out of the lower control arm bushing. - When installing the front subframe rear bolts, make sure both of the front subframe rear bolts are fully engaged in their cage nuts before tightening to specification. Loosen the 2 front subframe rear bolts. Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Page 2976 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 6356 Audio System - Front Door Speaker Buzzing Front Door Panel: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION BASIC PART NO. CODE 78237A05 12 Page 4832 Page 4689 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material 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 the vehicle as-built data and calibrated. 1. Remove the hydraulic control unit (HCU). 2. Remove the 3 ABS module screws. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. Remove the ABS module. 4. To install, reverse the removal procedure. System Diagnosis P1290 Page 1537 2. NOTE: Mark the hood latch position prior to removal of the bolts. Position the hood latch assembly aside. 1 Loosen the hood latch nut. 2 Remove the hood latch bolts. 3 Position the hood latch aside. 3. Detach the wiring harness pin-type retainers. 4. Remove the radiator support bracket bolt. 5. Remove the front impact severity sensor bolt. 6. Disconnect the electrical connector and remove the front impact severity sensor. Installation 1. Connect the electrical connector to the front impact severity sensor. 2. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Align the locator tabs of the front impact severity sensor to the openings in the radiator support bracket. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. Install the front impact severity sensor bolt. Tighten to 12 Nm (9 lb-ft). 4. Install the radiator support bracket bolt. - Tighten to 12 Nm (9 lb-ft). 5. Attach the wiring harness pin-type retainers. Page 6759 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 7463 L9-L10 Normal Operation When the brake pedal is applied, the stoplamp switch allows voltage to flow through circuit 511 (LG). Circuit 511 (LG) provides voltage to the high mounted stoplamp and the smart junction box (SJB). The SJB then provides voltage to the LH and RH rear lamps through circuits 22 (LB/BK) and 810 (RD/LG), respectively. Possible Causes - circuit 22 (LB/BK) short to voltage - circuit 511 (LG) short to voltage - circuit 810 (RD/LG) short to voltage - stoplamp switch - speed control module - SJB - PCM - ABS module System Diagnosis P0068 Page 2658 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 2087 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Locations View 151-7 (Engine, front) Page 7327 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 2271 Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler. ^ Inspect the oil cooler. ^ To install, tighten to 34 Nm (25 ft. lbs.). 10. To install, reverse the removal procedure. 11. Fill and bleed the engine cooling system. 12. Fill the engine with clean engine oil. Page 7777 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 5173 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 7174 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open 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 7646 Horn: Service and Repair HORN Removal and Installation 1. Remove the front bumper cover. 2. NOTE: LH shown, RH similar. Remove the horn bolt and the horn. Disconnect the electrical connector. - To install, tighten to 23 Nm (17 lb-ft). 3. To install, reverse the removal procedure. Page 4739 Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 3938 Shift Cable: Service and Repair Transmission Selector Lever Cable Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector level in the (D) position. Page 7469 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 308 P0462 Page 1596 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Removal and Installation 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 seat must be in rearward position. 1. Depower the system. 2. Disconnect the seat position sensor electrical connector. 3. Remove the screw and the seat position sensor. 4. To install, reverse the removal procedure. 5. Repower the system. Recall - Interior Impact Non-Compliance Technical Service Bulletin # 06C12 Date: 060512 Attachment I - Administrative Information Page 29 P0061 Page 6159 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Removal and Installation 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 seat must be in rearward position. 1. Depower the system. 2. Disconnect the seat position sensor electrical connector. 3. Remove the screw and the seat position sensor. 4. To install, reverse the removal procedure. 5. Repower the system. Page 294 P0452 Page 1968 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 5418 4. Using the special tools, remove the wheel hub. 5. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 6. Remove the wheel bearing snap ring from the wheel knuckle. FWD vehicles 7. Using the special tools, remove the wheel bearing from the wheel knuckle. 4WD vehicles 8. Using the special tools, press the wheel bearing race from the wheel knuckle. Installation All vehicles Page 3695 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Page 3678 Page 961 Electronic Throttle Monitor Operation (Part 1) Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Page 2259 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Engine Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ insufficient oil ^ oil leakage ^ worn or damaged oil pump ^ oil pump screen cover and tube ^ excessive main bearing clearance ^ excessive connecting rod bearing clearance ^ chain tensioner leak Page 7286 The warning messages can interrupt the display until cleared or reset by the driver. The warning messages are either single cycle, non-resettable, or repetitive warning messages. The single cycle warning messages display once whenever the ignition switch is turned to the ON position or a fault occurs in a system, and can be cleared by pressing the RESET button. The single cycle warning messages are: liftgate ajar - liftgate glass ajar - service emission system - low brake fluid - service brake system - check left headlamp - check right headlamp - check left turn lamps - check right turn lamps - check left high beam - check right high beam - check brake lamps - check parking lamps - washer fluid low - check fuel cap - change oil soon - change oil now - low fuel - service 4x4 - turn signal on The repetitive warning message (park brake ON) displays whenever the ignition switch is turned to the ON position or a fault occurs in a system. The repetitive warning message appears again after a 10-minute interval until the condition is corrected. The non-resettable warning messages display whenever the ignition switch is turned to the ON position 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: high engine temperature - driver door ajar - passenger door ajar - driver rear door ajar - passenger rear door ajar Temporary Alert Messages The temporary alert display interrupts the current display to show the status of an event that has just happened. The temporary alert messages are: 4x4 locked temporarily - 4x4 disabled temporarily - 4x4 auto restored PRINCIPLES OF OPERATION - ESCAPE HYBRID The message center electronic functions use both hardwired and CAN circuits to receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - which module controls the output of the feature. Display Information The display modes are: information - setup - system check - warning - temporary alert Various message center information can be selected and reset by pressing the following buttons: SET - INFO The select display and the reset display time-out and default to the information display mode. The temporary alert display interrupts the current display Page 1151 View 151-21 (Passenger Seat) Locations View 151-4 (Engine Compartment, 2 Of 2) Page 5327 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can C110-C311 Multiple Junction Connector: Diagrams C110-C311 Page 7663 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 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 7661 Symbols Part 5 Page 1686 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 Diagrams Page 3465 Page 5282 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Service and Repair Oil Change Reminder Lamp: Service and Repair ENGINE OIL CHANGE SOON/ENGINE OIL CHANGE NOW Displayed when the engine oil life remaining is 5% or less. When oil life left is between 5% and 0%, the ENGINE OIL CHANGE SOON message will be displayed. When oil life left reaches 0%, the ENGINE OIL CHANGE NOW message will be displayed. An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 12 months] perform the following. 1. Press the SET control to access the system check function. 2. Press and release the SET control to display "OIL CHNG XXX% HOLD SET NEW". 3. Press and hold the SET control for 2 seconds to display "OIL CHANGE SET TO 100%". Page 2953 Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Specifications Firing Order: Specifications Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Locations View 151-8 (Engine, rear) Page 475 P1129 Page 6660 1. For additional information, refer to the procedures. Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment Front Camber and Caster Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front strut upper mounting bracket nuts. 3. Push the front strut mounting bracket downward and turn it to the desired position to set the camber and caster. Both camber and caster for the front suspension are adjustable. 4. NOTE: Notice the position of the strut rod in each position Use the following table for LH side camber and or caster adjustment. Page 3359 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 4988 Page 3091 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. System Diagnosis P1550 Page 585 P1386 Page 6045 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 5831 Page 5929 5. WARNING: If the air bag deployment chute is not properly positioned, the side air bag may not deploy properly. Install the side air bag module deployment chute and J-clips around the side air bag module and seat backrest frame. 6. Install the hook and loop fastener around the seat backrest frame. 7. Roll the seat trim cover down in position and attach the hook and loop strips. 8. Feed the seat back trim cover rear J-clip through seat between the seat backrest and seat cushion. 9. Fully recline the seat backrest. 10. Attach the seat back trim cover J-clips. 11. Move seat backrest to the upright position. Seats with manual lumbar adjust Page 7025 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 5873 Impact Sensor: Diagrams Side Impact Sensor Page 2635 Camshaft Position Sensor: Diagrams Page 132 P0190 - P0194: Testing and Inspection P0191 P0191 (Part 1) P0191 (Part 2) Page 6318 G1-G3 Page 4974 Differential Seals - LH Seals and Gaskets: Service and Repair Differential Seals - LH Differential Seals-LH Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. Page 5703 Compressor Connection Diagrams Locations View 151-17 (Full Body, Right Rear - 1 Of 2) System Diagnosis P1582 Page 1501 Camshaft Position Sensor: Diagrams General Procedures Camshaft: Service and Repair General Procedures Camshaft Journal Diameter 1. Measure each camshaft journal diameter in 2 directions. ^ If out of specification, install new components as necessary. Camshaft End Play-OHC Engines Special Tool(s) 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft end play. 2. Position the camshaft to the rear of the cylinder head. 3. Zero the indicator. 4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. ^ If camshaft end play exceeds specifications, install new camshaft and recheck end play. ^ If camshaft end play exceeds specification after camshaft installation, install a new cylinder head. Camshaft Surface Inspection Page 3164 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 2177 Crankshaft: Service and Repair Crankshaft End Play Special Tool(s) 1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play. 2. Position the crankshaft to the rear of the cylinder block. 3. Zero the indicator. 4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. ^ If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing. P2110 P2110 Page 3387 Exploded View Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the air cleaner intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Page 6192 Page 3848 2. Remove the transaxle drain plug and drain the transmission fluid. 3. Remove the RH halfshaft. 4. If equipped, remove the Power Takeoff (PTO). 5. If the vehicle is equipped with a PTO, use the special tools to remove the RH differential seal. 6. If the vehicle is not equipped with a PTO, use the special tools to remove the RH differential seal. Installation 1. If the vehicle is equipped with a PTO, use the special tools to install the RH differential seal. Page 4745 - To install, tighten to 8 Nm (71 lb-in). 19. Position the BJB terminal aside. 20. Disconnect the BJB electrical connector. 21. Disconnect the retainers fastening the battery cables to the battery tray. 22. Remove the battery cables. 23. To install, reverse the removal procedure. Page 4188 4. CAUTION: Make sure to use the special tool when installing the intermediate shaft. Failure to use the special tool may result in transmission oil leaks. To install, reverse the removal procedure. ^ Apply a thin coat of grease to the splines of the intermediate shaft. 5. Check and fill the transaxle fluid as necessary. Disassembly and Assembly Halfshaft Special Tool(s) Material Disassembly 1. Remove the front drive halfshaft. 2. Secure the front drive front drive halfshaft in a vise using protective jaw covers. 3. Remove the 2 inner CV boot clamps. Page 6077 Seat Sensor/Switch: Locations Seat Belt Buckle Sensor View 151-20 (Driver Seat) Page 7983 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 5497 10. NOTE: The auxiliary climate control housing must be slightly repositioned to remove the screws. Remove the auxiliary airflow mode door actuator screws. ^ Disconnect the rod. ^ To install, tighten to 2 Nm (18 lb-in). 11. Remove the auxiliary airflow mode door actuator 12. NOTE: The auxiliary climate control housing must be installed behind the lower portion of the D-pillar bracket. When installed correctly, the auxiliary climate control housing bolt will go through the D-pillar bracket first, then through the housing mounting location. NOTE: Before the D-pillar trim panel and LH quarter trim panel are installed, correct auxiliary mode door actuator operation can be verified by carrying out the Traction Battery Control Module (TBCM) self-test while visually verifying correct actuator operation. To install, reverse the removal procedure. Page 2051 Disclaimer Page 5184 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 5943 Air Bag Control Module: Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6133 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system. - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated seat). Always make sure the correct OCS service kit is installed. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing of 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 5-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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" once rezeroing of the OCS system is complete. - 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. - To identify between a production OCS system and a OCS system service kit, inspect the OCS ECU electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCS ECU. An OCS system service kit (OCS service kit) has the OCS ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 10-pin connector between the OCS ECU and the seat wiring harness. - 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor system is found only on the front passenger seat. The front passenger seat occupant classification sensor (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 bladder when the 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 pressure sensor, then electronically communicated to the OCS electronic control unit. Based on programmed limits, the OCS electronic control unit will inform the restraints control module (RCM), via a High Speed Controller Area Network (CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. 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 is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators or the owner literature. Page 4688 Page 4927 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 1008 Liftgate Ajar Switch Page 2017 Relay Box: Diagrams Smart Junction Box (SJB) Page 1711 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Page 3333 EGR Valve: Description and Operation EXHAUST GAS RECIRCULATION (EGR) VALVE Typical EGR Valve Test Graph The EGR valve in the DPFE system is a conventional, vacuum-actuated. 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 repair specifications on flow rate is impractical. The on-board diagnostic (OBD) system monitors the EGR valve function and triggers a diagnostic trouble code (DTC) if the test criteria is not met. The EGR valve flow rate is not measured directly as part of the diagnostic procedures. Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Testing and Inspection Front Steering Knuckle: Testing and Inspection Diagnostic Routine-Vibration 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. Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Page 2362 13. Remove the special tool. 14. NOTE: Only turn the engine in the normal direction of rotation. Turn the engine 2 complete revolutions. 15. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft until the No. 1 piston is at TDC. 16. Install the special tool. 17. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Using the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt, check the position of the crankshaft pulley. ^ If it is not possible to install the bolt, correct the engine timing. Page 3198 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. To install, reverse the removal procedure. Page 2310 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the flexplate or flywheel. 3. CAUTION: If the oil pan is not removed damage to the rear oil seal retainer joint can occur. Remove the 17 bolts and the oil pan. 4. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate. Installation 1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft. Page 7133 View 151-14 (Under Dash Panel, LH Side) Page 7933 Window Frame: Service and Repair Rear Door Glass Top Run REAR DOOR GLASS TOP RUN Removal and Installation 1. Remove the rear door window regulator. 2. Position the rear door window glass to the full down position. 3. Remove the 2 screws and the rear door exterior sail panel. 4. Remove the interior door glass weatherstrip. 5. Remove the exterior door glass weatherstrip. 6. Remove the 2 rear door glass top run bolts. - To install, tighten to 6 Nm (53 lb-in). 7. Position the rear door window glass down and forward. 8. Remove the rear door glass top run. 9. To install, reverse the removal procedure. Locations View 151-11 (Manual Transmission) Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt ........................................................................................................................ ..................................................... 65 Nm (48 ft. lbs.) Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Page 3758 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 7493 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. Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Locations View 151-13 (Behind Dash Panel) Page 6051 when inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. NOTE: The RH rear safety belt retractor is shown, LH side similar. 1. Remove the rear quarter trim panel. 2. Remove the rear safety belt retractor anchor bolt. - To install, tighten to 47 Nm (35 lb-ft). 3. Remove the bolt and the rear safety belt retractor. - To install, tighten to 47 Nm (35 lb-ft). 4. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. - Make sure that after the rear safety belt retractor is installed, the retractor is not in the automatic locking retractor (ALR) mode. Page 5958 Page 7439 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 5019 Page 7526 Special Tool(s) Page 6735 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 468 P1117 Page 6465 Symbols Part 4 Page 3423 Mechanical Returnless Fuel Pump Module (FPM) Page 4323 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 5949 2. Remove the lower LH center instrument panel finish panel. 3. Position back the carpet on the LH and RH tunnel to access the RCM. 4. Disconnect the large 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 large RCM electrical connector. 5. Disconnect the small RCM electrical connector. 6. Remove the 3 bolts and the RCM. Installation Page 835 P2272 Locations View 151-20 (Driver Seat) Page 1424 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Service and Repair Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Front Brake Pad: Service and Repair Front Brake Pads Material Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake caliper clip. 3. Remove the 2 brake caliper dust boot caps. 4. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.) on disc-drum system. ^ To install, tighten to 45 Nm (33 ft. lbs.) on 4-wheel disc brake system. 5. CAUTION: Do not allow the brake caliper to hang by the brake caliper jounce hose. Remove the brake caliper and support the brake caliper to the vehicle. 6. Remove the inboard brake pad from the brake caliper. 7. Remove the outboard brake pad from the brake caliper anchor plate. 8. To install, reverse the removal procedure. Page 5121 Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Removal 1. Remove the brake disc. 2. Remove and discard the wheel hub nut. 3. Using the special tool, separate the outer CV joint spindle from the wheel hub. 4. Remove the cotter pin and the tie-rod end-to-knuckle nut. 5. CAUTION: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod end boot while installing the special tool. Specifications Intake Manifold: Specifications Intake manifold bolts ............................................................................................................................ .................................................... 18 Nm (13 ft. lbs.) Page 3414 Page 2025 Relay Box: Application and ID Battery Junction Box Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 794 P2111 Forward Crash Sensor Page 7008 Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Make sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The passenger seat is equipped with an occupant classification sensor (OCS) system and is replaced as an assembly. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the 4 front seat track bolts. - To install, tighten to 23 Nm (17 lb-ft). 3. If equipped, disconnect the front seat cushion heated seat grid electrical connector. 4. Remove the front seat cushion cover from the front seat cushion pan. 5. To install, reverse the removal procedure. 6. Install the front seat and repower the supplemental restraint system (SRS). Page 7763 Page 6661 Trunk / Liftgate Latch: Service and Repair Liftgate Latch LIFTGATE LATCH Removal and Installation 1. Remove the liftgate trim panel. 2. Disconnect the liftgate ajar switch electrical connector. 3. Disconnect the liftgate latch actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. 4. Remove and discard the 3 liftgate latch bolts. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the liftgate latch. 6. To install, reverse the removal procedure. - Lubricate the liftgate latch to striker surfaces with Krytox grease after installation. Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 6321 73III Automotive Meter Page 3071 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 5925 - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - If a side air bag deployment took place a new seat back pad, trim cover, and side air bag module must be installed. The seat back frame should be replaced if necessary. - When replacing the side air bag after deployment, refer to Seats. - 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. - Passenger seat side air bag module shown, driver side similar. All seats 1. Remove the front seat and depower the system. 2. Remove the inboard seat cushion side shield. 1 Remove the rear screw. 2 Push the inboard seat cushion side shield forward to release. 3. Loosen the safety belt buckle pretensioner bolt. 4. WARNING: Note the position of the wiring harness, to aid installation. An incorrectly routed wiring harness could become damaged when the seat is moved. Failure to follow this instruction may result in personal injury. Disconnect the side air bag module electrical connector and detach the wiring retainers. Seats with manual lumbar adjust 5. Turn the manual lumbar knob clockwise until it stops, releasing all tension on the manual lumbar support cable. Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 7175 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch 45 degrees counterclockwise to disengage it from the bracket. Installation CAUTION: The initial installation of a speed control deactivator switch allows for adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. - Turn the lock knob counterclockwise until the first click is felt. 2. Press and hold the brake pedal. 3. Install the speed control deactivator switch. 1 Position the speed control deactivator switch in the bracket and rotate clockwise 45 degrees. Page 3809 6. Loosen the special tool bolt. ^ When the spring tension is released, remove the special tool. 7. Install the transmission fluid cooler line and bolt. ^ Tighten to 13 Nm (10 ft. lbs.). 8. Install the LH splash shield and the 7 retainers. ^ Tighten to 10 Nm (89 inch lbs.).. 9. Start the vehicle. Place the transmission range selector lever in each gear and allow to engage. Check for leaks. 10. Check the transmission fluid. Page 4099 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. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP leak check monitor. Page 4069 3. Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and spring ends that are higher or lower than the rest. 4. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury. CAUTION: Loosen the bolts evenly to prevent pressure plate damage. Remove the bolts, clutch pressure plate and clutch disc. 5. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Using a suitable commercial alcohol based solvent, clean the clutch pressure plate. 6. Inspect the clutch pressure plate surface for burn marks, scores, flatness or ridges. 7. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation. NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface. NOTE: Install a new clutch disc if any of the following conditions are present. Inspect the clutch disc for: ^ oil or grease saturation ^ worn or loose facings ^ warpage or loose rivets at the hub ^ wear or rust on the splines 8. Check the clutch disc runout and wear. Installation 1. Using the special tool, position the clutch disc on the flywheel. Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Page 4336 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 4031 8. Install the LH splash shield. 9. Install the shift cable and bracket. ^ Tighten to 23 Nm (17 ft. lbs.). 10. Connect the shift cable end. 11. Connect the vent hose to the main control cover. Page 7895 Power Window Switch: Testing and Inspection Window Adjust Switch Page 3020 well as with the international standards organization (ISO) 9141 communication network. If communication cannot be established, the diagnostic tool and the DLC C251 must be checked for damage. If the diagnostic tool and the DLC C251 are OK, circuits 956 (OG/LG), 570 (BK/WH), and 57 (BK) must be checked for an open condition. Possible Causes - DLC C251 - diagnostic tool - circuit 57 (BK) open - circuit 570 (BK/WH) open - circuit 956 (OG/LG) open Symptom Chart (Part 1) Page 6286 Driver/Vehicle Information Display: Pinpoint Tests Compass Sensor Module C909 Instrument Cluster C220 Page 1671 System Diagnosis P076x Page 7328 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Page 7810 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 6703 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Page 7825 Y2-Y4 Page 6995 14. Position the seat position sensor and bracket onto the inboard track, then install the nuts holding the inboard track to the upper support assembly lift links. 15. Check to make sure the index marks on the inboard track C-channel and plastic coated slide are still in alignment. - The index marks on the inboard track C-channel and plastic coated slide must align at this step. If the index marks do not match up, repeat Steps 12 through 14. 16. CAUTION: - The splines on the stud are very shallow. Do not use excessive force while turning the nut. - If the stud turns free from the seat track while installing the nut, a new seat track must be installed. Install the seat position sensor bracket nut. 17. Attach the seat motor wiring harness to the seat track. Page 6437 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: Customer Interest SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Service and Repair High Pressure Sensor / Switch: Service and Repair HIGH PRESSURE CUTOFF SWITCH Removal and Installation 1. Disconnect the high pressure cut-off switch electrical connector. 2. Remove the high pressure cut-off switch. 3. NOTE: A new O-ring seal lubricated with clean mineral oil must be installed before installing a new switch. To install, reverse the removal procedure. Page 3023 Configurable Modules The vehicle contains the following configurable modules: Smart Junction Box (SJB) - Anti-lock Brake System (ABS) Module - Instrument Cluster - Powertrain Control Module (PCM) Programmable Parameters Index Page 6803 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 6089 Impact Sensor: Locations Side Impact Sensor View 151-16 (Full Body, Left Rear - 2 Of 2) Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Bar Bushing Removal and Installation CAUTION: When installing the stabilizer bar bushings, make sure the bushings are correctly oriented with the bushing flanges in the up position and the bushing split pointing to the rear of the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 bolts and the stabilizer bar bushing bracket. ^ To install, tighten to 70 Nm (52 ft. lbs.). 3. NOTE: Inspect the stabilizer bar bushing for wear. If necessary, install a new part. Remove the stabilizer bar bushing. 4. To install, reverse the removal procedure. Page 7303 D3 Continued Normal Conditions The compass sensor module receives voltage from circuit 1002 (BK/PK) and is grounded through circuit 570 (BK/WH). The compass sensor module communicates the vehicle direction to the instrument cluster, which is displayed in the message center. The compass sensor module uses circuit 702 (WH/BK) and circuit 703 (WH/OG) to communicate to the instrument cluster. Possible Causes - circuit 1002 (BK/PK) open - circuit 570 (BK/WH) open - circuit 702 (WH/BK) open or short to ground - circuit 703 (WH/OG) open or short to ground - compass sensor module Test E: The Compass Is Inaccurate PINPOINT TEST E: THE COMPASS IS INACCURATE Page 3689 Page 2075 Disclaimer Specifications Valve Clearance: Specifications NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. If any tappets do not measure within specifications, install new tappets in these locations. Page 2629 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 7737 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 7422 Page 3620 Throttle Position Sensor: Diagrams Page 1709 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 3899 Shift Interlock: 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. 37-1 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: Locations View 151-14 (Under Dash Panel, LH Side) Steering - Front End Rattle Noise Turning On Bumps Power Steering Line/Hose: All Technical Service Bulletins Steering - Front End Rattle Noise Turning On Bumps TSB 06-17-3 09/04/06 STEERING NOISE - CLUNK/RATTLE FORD: 2005-2007 Escape MERCURY: 2005-2007 Mariner This article supersedes TSB 05-25-9 to update the vehicle model years. ISSUE Some 2005-2007 Escape and Mariner vehicles may exhibit a single or multiple clunk/rattle noise from the front end. This noise typically occurs with the front wheels turned while hitting a bump such as when turning into a driveway. It is usually more noticeable with hot engine and ambient air temperatures, and may easily be mistaken for loose sheet metal or a loose suspension/underhood component. The cause of this noise is an audible hydraulic pressure spike in the power steering system. ACTION Install a new power steering return line which contains an internal orifice to reduce the pressure spike. SERVICE PROCEDURE 1. Remove the power steering reservoir cap. 2. Using a suitable suction device, remove the power steering fluid from the reservoir. 3. Disconnect the power steering return hose from the reservoir by loosening the constant tension clamp. 4. Remove and discard the lower return line hose clamp, then remove the hose. 5. Install the new return line with the crimped band away from the reservoir. The pre-installed constant tension clamp will retain the reservoir end of the hose. 6. Install and tighten the screw clamp on the lower end of the hose. 7. Refill the system with Mercon® or Mercon(R)-V fluid and purge the air as described in Section 211-00 of the Workshop Manual. NOTE DO NOT FILL WITH TYPE-F FLUID. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061703A 2005-2007 Escape/Mariner: 0.5 Hr. Replace Power Steering Return Line (Do Not Use With 3713AE) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 Page 530 P1261 Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 7869 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 6225 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 5618 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 6092 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 6968 Symbols Part 4 Page 3106 Page 5285 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 6704 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 7255 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 5102 Difference From Standard Position (LH Side) 5. NOTE: Notice the position of the strut rod in each position. Use the following table for the RH side camber and or caster adjustment. Page 7449 90-2 Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. 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 2521 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 2041 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Page 6701 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 6580 Disconnect the battery. 2. Open the cover, remove the screw and the interior door handle bezel. 3. Remove the door handle cup screw. 4. Remove the front door trim panel cover, screws and the front door trim panel. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Page 5315 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 7259 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 1821 Hose/Line HVAC: Service and Repair Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Compressor Connection Page 2738 Page 837 P2274 Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE PIPE Page 3974 Transmission Cooler: Removal and Replacement Auxiliary Transmission Fluid Cooler Auxiliary Transmission Fluid Cooler Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front bumper cover. 3. Disconnect the transmission fluid cooler tube clamps and disconnect the rubber hoses from the auxiliary cooler. 4. Remove the bolts for the auxiliary and remove the cooler. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Fill the transaxle with clean automatic transmission fluid. 6. To install, reverse the removal procedure. Cooler Bypass Valve Cooler Bypass Valve Locations View 151-12 (Dash Panel) Description and Operation EGR Control Module: Description and Operation EGR SYSTEM MODULE (ESM) Overview EGR System Module (ESM) The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional DPFE system, however the various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a traditional DPFE system. The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional tests that monitor various aspects of the EGR system operation. First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405 P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403). NOTE: EGR normally has large amounts of water vapor that are the result of the engine combustion process. During cold ambient temperatures, under some circumstances, water vapor can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to prevent MIL illumination for temporary freezing, the following logic is used. If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines that the malfunction is no longer present, the EGR system will be enabled and normal system operation will be restored. If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the malfunction has been detected on 2 consecutive driving cycles. After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is evaluated to determine the amount of EGR system restriction. If the differential pressure is below a calibrated threshold, a low flow malfunction is indicated (P0401/P0406). Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero requested EGR flow to carry out the high flow check. If the differential pressure exceeds a calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR valve seat (P0402). If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles for the EGR monitor to be set to a ready condition. Page 1210 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch 45 degrees counterclockwise to disengage it from the bracket. Installation CAUTION: The initial installation of a speed control deactivator switch allows for adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. - Turn the lock knob counterclockwise until the first click is felt. 2. Press and hold the brake pedal. 3. Install the speed control deactivator switch. 1 Position the speed control deactivator switch in the bracket and rotate clockwise 45 degrees. Page 2974 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 4293 Transmission Mount: Service and Repair Front Transaxle Front Support Insulator Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. System Diagnosis P2020 Steering - Front End Rattle Noise Turning On Bumps Power Steering Line/Hose: Customer Interest Steering - Front End Rattle Noise Turning On Bumps TSB 06-17-3 09/04/06 STEERING NOISE - CLUNK/RATTLE FORD: 2005-2007 Escape MERCURY: 2005-2007 Mariner This article supersedes TSB 05-25-9 to update the vehicle model years. ISSUE Some 2005-2007 Escape and Mariner vehicles may exhibit a single or multiple clunk/rattle noise from the front end. This noise typically occurs with the front wheels turned while hitting a bump such as when turning into a driveway. It is usually more noticeable with hot engine and ambient air temperatures, and may easily be mistaken for loose sheet metal or a loose suspension/underhood component. The cause of this noise is an audible hydraulic pressure spike in the power steering system. ACTION Install a new power steering return line which contains an internal orifice to reduce the pressure spike. SERVICE PROCEDURE 1. Remove the power steering reservoir cap. 2. Using a suitable suction device, remove the power steering fluid from the reservoir. 3. Disconnect the power steering return hose from the reservoir by loosening the constant tension clamp. 4. Remove and discard the lower return line hose clamp, then remove the hose. 5. Install the new return line with the crimped band away from the reservoir. The pre-installed constant tension clamp will retain the reservoir end of the hose. 6. Install and tighten the screw clamp on the lower end of the hose. 7. Refill the system with Mercon® or Mercon(R)-V fluid and purge the air as described in Section 211-00 of the Workshop Manual. NOTE DO NOT FILL WITH TYPE-F FLUID. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061703A 2005-2007 Escape/Mariner: 0.5 Hr. Replace Power Steering Return Line (Do Not Use With 3713AE) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Page 6091 View 151-18 (Full Body, Right Rear - 2 Of 2) System Diagnosis P1674 Page 3009 F7-F9 Page 3470 2 Press the quick connect coupling locking tab into position. Pull on the fitting to make sure it is fully engaged. 5. Install the fuel vapor tube. - Attach the fuel vapor tube retainers. 6. CAUTION: Make sure the fuel vapor 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 tubes before inserting the tubes into the connectors. Connect the fuel vapor tube quick connect couplings to the intake manifold and the EVAP canister purge valve. 7. Install the LH lower splash shield. 8. CAUTION: Make sure the fuel supply 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 supply tube and connect the quick connect coupling. 9. NOTE: - Make sure the collar on the fuel tube is inserted fully into the quick connect coupling before the locking tang is locked. - Apply clean engine oil to the end of the tube before inserting a tube into the connector. Connect the fuel tube to fuel rail quick connect coupling. Connect the quick connect coupling to the tube. - Press the quick connect coupling locking tab into position. - Pull on the fitting to make sure it is fully engaged. 10. Connect the battery ground cable. 11. Turn the ignition key to the ON position to pressurize the fuel system. 12. Visually inspect the fuel system for leaks. 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 7289 Driver/Vehicle Information Display: Diagnostic Trouble Code Descriptions B1205-B1212 Page 620 P1464 Page 3572 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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 7780 Symbols Part 2 Page 3063 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the catalyst monitor sensor electrical connector. Page 7621 Symbols Part 5 Page 3257 Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced. - Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Cam Timing (VCT) System Variable Cam Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system 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 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Page 1018 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The 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 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. 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 carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC if a SRS fault exists. The air bag indicator will flash the LFC 5 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, to the diagnostic 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 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides 150 ms of backup power to deploy the front air bags and pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. P2105 P2105 Page 1805 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. Page 1582 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. CAUTION: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and detach OCS ECU from the seat cushion pan. 9. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, ECU and connectors) through the seat cushion pan opening. Installation 1. Bend the retaining tab back on the pressure sensor component bracket. Page 7423 Backup Lamp Switch: Service and Repair REVERSING LAMP SWITCH Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Page 3658 Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 4983 Page 4477 View 151-10 (Automatic Transmission) P0217 P0217 Page 6987 6. Remove the two bolts, then remove the seat position sensor interrupt bracket. 7. Detach the seat motor wiring harness from the seat track. 8. NOTE: - If not correctly positioned, the seat track motor assembly cannot be removed from the seat track. - If the seat track does not move, manually turn the drive tube while applying power to the horizontal motor. Position the seat track horizontally by applying power and ground to the seat track motor pins. Position the outboard track most of the way forward so that two teeth are showing next to the outboard retainer clip and a flat spot on the drive tube is positioned upward. Page 4224 Drive/Propeller Shaft: Service and Repair Driveshaft Runout and Balancing Driveshaft Runout and Balancing Special Tool(s) 1. Remove the rear tires. ^ Install the lug nuts to retain the brake drums or brake disc. 2. Check the rear driveshaft attachment. If there are any worn parts, new parts need to be installed. 3. Using the special tool, measure the runout at the front, the center, and the rear of the driveshaft. 4. If the runout measurements are within specifications, go to Step 13. 5. If the runout measurements exceed the specifications at the front or the center, then install a new driveshaft. 6. If the runout measurement exceeds the specifications at the rear, mark the rear runout high point on the driveshaft. 7. Scribe alignment marks on the driveshaft and the axle pinion flange. 8. Index the driveshaft. 9. Using the special tool, measure the runout at the rear of the driveshaft. 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: Page 5941 ^ 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 5804 Air Bag: Locations Side Air Bag Module View 151-20 (Driver Seat) Page 4962 Page 2692 Manifold Pressure/Vacuum Sensor: Diagrams Deactivator Switch View 151-14 (Under Dash Panel, LH Side) Page 6761 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Page 5059 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 7536 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 1893 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ..................................................................................................................................................... ............. SAE 80W-90 Premium Rear Axle Lubricant Output Shaft Speed (OSS) Sensor Page 2577 GEN II ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 5128 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 5807 View 151-17 (Full Body, Right Rear - 1 Of 2) 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 Audio System - Front Door Speaker Buzzing Speaker: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION BASIC PART NO. CODE 78237A05 12 Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Diagrams Page 6664 Trunk / Liftgate Latch: Service and Repair Liftgate window Latch LIFTGATE WINDOW LATCH Removal and Installation NOTE: Make sure the liftgate window glass is in the raised position. 1. Remove the liftgate trim panel. 2. Disconnect the liftgate window latch. 1 Disconnect the liftgate window latch ajar switch electrical connector. 2 Open the clip and disconnect the actuating rod. 3. NOTE: Mark the position of the liftgate window latch prior to removing the liftgate window latch bolts. Remove the 2 liftgate window latch bolts and the liftgate window latch. To install, tighten to 7 Nm (62 lb-in). 4. NOTE: The liftgate window latch must be checked to make sure the latch is installed and aligned correctly. To install, reverse the removal procedure. Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Locations View 151-10 (Automatic Transmission) Page 6468 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 1021 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Position the RCM and install the 3 bolts. Tighten to 11 Nm (8 lb-ft). 2. Connect the small RCM electrical connector. 3. Make sure the connector position assurance lever is in the full release position before attempting to connect the large RCM electrical connector. 4. CAUTION: Putting the large RCM electrical wiring 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 wiring connector into the RCM. - CAUTION: Do not push the connector to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. Service and Repair Fluid - M/T: Service and Repair Transaxle Draining and Filling Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the drain plug and drain the fluid. 3. NOTE: Use a new gasket and apply sealant on the drain plug. Install the drain plug. ^ Tighten to 35 Nm (26 ft. lbs.). 4. Remove the fill level inspection plug. Page 164 P0231 Engine Crankshaft - Pulley Bolt Service Precautions Crankshaft: Technical Service Bulletins Engine Crankshaft - Pulley Bolt Service Precautions TSB 06-21-4 10/30/06 2.3L/2.0L DURATEC - NO START/POSSIBLE ENGINE DAMAGE - INSTALL SPECIAL SERVICE TOOLS PRIOR TO REMOVING CRANKSHAFT PULLEY BOLT FORD: 2003-2007 Focus 2006-2007 Fusion 2001-2007 Ranger 2005-2007 Escape Hybrid, Escape MERCURY: 2006-2007 Milan 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 06-16-6 to include symptoms, labor operations, and parts. ISSUE Some 2001-2007 MY vehicles equipped with a 2.0L or 2.3L Duratec Engine may exhibit no start, loss of engine timing or scraping noise at crankshaft pulley at front of engine. These engines, (excludes 2.0L SPI and Zetec engines) may experience engine damage if the crankshaft pulley bolt is loosened during service WITHOUT FIRST INSTALLING THE SPECIAL SERVICE TOOLS PER THE WORKSHOP MANUAL PROCEDURE. The crankshaft pulley bolt also retains the crankshaft cam drive sprocket which is NOT keyed to the crankshaft, so valve timing may shift if the crankshaft pulley bolt is loosened. If this occurs, the pistons may contact and damage the valves. ACTION Before ANY repair requiring loosening or removal of the crankshafl pulley bolt, engine valve timing MUST be locked by the Special Service Tools identified in the online Workshop Manual, Section 303-01 (In-Vehicle Repair: Crankshaft Pulley). Do not attempt to start the engine without verifying engine cam timing. SERVICE PROCEDURE CAUTION FAILURE TO FOLLOW THE PROCEDURE EXACTLY CAN RESULT IN SERIOUS ENGINE DAMAGE. SERVICE TOOLS REQUIRED ARE: 1. Crankshaft Timing Peg ESST Number 303-507 is 2-1/8" (54 mm). 2. Camshaft Alignment Plate ESST Number 303-465. 3. Holding Fixture ESST Number 205-126. 4. Adaptor 205-072-02. Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) 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 ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 5562 Compressor Clutch: Service and Repair CLUTCH AND CLUTCH FIELD COIL Special Tool(s) Special Tool(s) Service and Repair Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) Material 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 anti-lock brake system (ABS) module can be damaged if exposed to these charges. 1. Disconnect the battery. 2. Remove the air cleaner and the air cleaner outlet pipe. Page 6782 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 64 P0122 Page 3360 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. System Diagnosis P2014 Page 5616 1. Fabricate a cleaning tool from a 1/8-inch diameter brazing rod. 2. Cut an abrasive pad 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 1 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 4924 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 467 P1116 Page 2026 Page 1462 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Vehicle - Tow Capability/Service Kit Requirements Towing Information: Technical Service Bulletins Vehicle - Tow Capability/Service Kit Requirements TSB 06-7-1 04/17/06 NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape, Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac LINCOLN: 2006 Mark LT MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart. ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral tow capability for specific vehicle applications, and to determine if a Service Kit is required to make the vehicle neutral tow capable. Page 5521 Install Center Finish Panel) 042513D Register Replace All Vents 0.4 Hr. (Includes Time To Remove And Install Center Finish Panel) DEALER CODING CONDITION BASIC PART NO. CODE 19893 41 Disclaimer Page 6732 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 6439 Symbols Part 3 Page 7212 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 6569 Disclaimer Page 7641 A2-A3 Page 2444 Radiator Cooling Fan Motor: Service and Repair Cooling Fan Motor and Shroud Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the radiator grille. 3. Remove the front impact severity sensor. 4. Remove the 4 bolts and the 2 radiator brackets. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Remove the center support lower bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 6. Remove the nut and the center support. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Disconnect the cooling fan electrical connectors 8. Remove the 6 cooling fan bolts. ^ To install, tighten to 10 Nm (89 inch lbs.). 9. NOTE: Remove the LH cooling fan first and slide the RH cooling fan to the left side to remove. Remove the LH and the RH cooling fans. 10. To install, reverse the removal procedure. P0532 P0532 Page 5245 7. Using the special tool, install the outer CV joint into the wheel hub. 8. Install a new wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 9. Install the brake shoes. Drum brake vehicles 10. Connect the brake line to the wheel cylinder. ^ Tighten to 17 Nm (13 ft. lbs.). 11. Install the brake line bracket bolt. ^ Tighten to 22 Nm (16 ft. lbs.). 12. Connect the parking brake cable to the brake backing plate and install the parking brake cable bracket bolt. ^ Tighten to 23 Nm (17 ft. lbs.). 13. Install the parking brake shoes. All vehicles 14. Check and adjust the wheel alignment as necessary. Page 914 Deactivator Switch System Diagnosis P18xx Page 2498 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 7176 2 Connect the electrical connector. 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. Service and Repair Expansion/Freeze Plug: Service and Repair Cylinder Block Core Plug Replacement Special Tool(s) Material 1. Use a slide hammer or tools suitable to remove the cylinder block core plug. 2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug. 3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. Coat the cylinder block core plug and bore lightly with Threadlock - 262 and install the cylinder block core plug. Cup-Type 1. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface. CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore. Use a tool suitable to seat the cup-type cylinder block core plug. Expansion-Type Page 1814 Heater Hose To Block Connections Page 3251 Page 7787 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 6391 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 1311 Page 3932 6. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 7. Move the shifter through all gears from PARK to DRIVE several times making sure that the screw is not too tight. P1000 P1000 Page 2725 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 5702 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the RH splash shield. 4. If equipped, disconnect the engine block heater electrical connector. 5. Disconnect the A/C compressor electrical connector. 6. Remove the suction accumulator to compressor line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the suction accumulator to compressor line from the A/C compressor. 8. Remove the 2 suction accumulator to compressor line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the suction accumulator to compressor line spring lock coupling. 10. Remove the suction accumulator to compressor line. 11. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Page 6440 Symbols Part 4 Page 7788 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 5727 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Evacuation Using an R-134a Refrigerant Center NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Fuel System - Fuel Tank Slow to Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Fuel Tank Slow to Fill/Nozzle Shuts Off TSB 05-18-4 09/22/05 SLOW FUEL FILL - REPEAT FILLING STATION PUMP SHUT-OFF FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner ISSUE Some 2005-2006 Escape, Escape Hybrid and Mariner vehicles may exhibit a slow fuel fill or frequent filling station pump shut-offs, when refueling. ACTION Install a revised fuel tank filler pipe. The revised pipe has an improved radius to increase the fuel flow rate. Refer to Workshop Manual Section 310-01A. NOTE THIS CONDITION MAY STILL OCCUR ON SOME VEHICLES EVEN AFTER THE REVISED FUEL TANK FILLER PIPE HAS BEEN INSTALLED. SOME FILLING STATION PUMPS MAY DELIVER FUEL AT A RATE GREATER THAN THE DOT SPECIFICATION, OR MAY USE NOZZLE DESIGNS THAT ARE OVERLY SENSITIVE AND TEND TO SHUT OFF PREMATURELY. THIS IS NORMAL. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051804A 2005-2006 Escape/Mariner: 0.7 Hr. Install A Revised Filler Neck (Do Not Use With 9034A) 051804B 2005-2006 Escape Hybrid: 0.8 Hr. Install A Revised Filler Neck (Do Not Use With 9034A) DEALER CODING CONDITION BASIC PART NO. CODE 9A089 42 Disclaimer Parking Aid Sensor, Outer Left View 151-15 (Full Body, Left Rear - 1 Of 2) Page 7975 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Locations View 151-3 (Engine Compartment, 1 Of 2) Page 6482 Y1-Y2 Page 6485 Y5-Y6 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits 52 (YE) and 64 (DG) supply voltage to the trailer tow LH and RH stop/turn lamps respectively. Circuit 962 (BN/WH) supplies voltage to the trailer tow parking lamps. Ground for the trailer lamps is provided on circuit 57 (BK). Possible Causes - circuit 52 (YE) open, or short to ground - circuit 57 (BK) open - circuit 64 (DG) open, or short to ground - circuit 962 (BN/WH) open - trailer - SJB Test Z: The Trailer Lamps Are On Continuously PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY Z1 Page 4417 Seals and Gaskets: Service and Repair Halfshaft Seal RH Halfshaft Seal RH Special Tool(s) Page 5860 - 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. Depower the system. 2. Make sure the road wheels are in the straight-ahead position. 3. Remove the steering wheel. 4. If equipped with tilt steering, position the steering column completely downward and lock in place. 5. Push in where indicated, releasing the retaining tabs, and remove the upper steering column shroud. 6. Release the tilt column locking lever, allowing the steering column to move upward. Do not lock the tilt column locking lever back in place. 7. Remove the 3 screws and position the lower steering column shroud aside. 8. If installing the same clockspring, apply 2 strips of masking tape across the clockspring to prevent accidental rotation when the clockspring is removed. 9. Remove the 3 clockspring screws. 10. NOTE: If the clockspring is to be reinstalled, do not allow the clockspring to turn from its removal position. Partially remove the clockspring, then disconnect the 2 electrical connectors and remove the clockspring. Installation Vehicles needing clockspring recentering Locations View 151-7 (Engine, front) Page 7522 - circuit 760 (PK/LB) short to ground - circuit 700 (WH/VT) short to ground - circuit 701 (LB/BK) short to ground - ajar switches - SJB Test D: The Demand Lighting Is Inoperative PINPOINT TEST D: THE DEMAND LIGHTING IS INOPERATIVE D1-D2 Normal Operation Circuit 1005 (VT/OG) provides voltage to each demand lamp when activated. The demand lamps are grounded through circuit 570 (BK). The battery saver in the SJB deactivates the voltage and ground circuits after time-out. Possible Causes - circuit 1005 (VT/OG) open - circuit 570 (BK) open Test E: An Individual Interior Lamp Is Inoperative PINPOINT TEST E: AN INDIVIDUAL INTERIOR LAMP IS INOPERATIVE Page 3740 Page 7779 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises Suspension Strut / Shock Absorber: Customer Interest Suspension - Front Strut Pop/Rub/Grunt/Squeak Noises TSB 09-6-5 04/06/09 NOISE - FRONT STRUT AREA FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2001-2009 Escape, 2005-2009 Escape Hybrid, Mariner and 2006-2009 Mariner Hybrid vehicles may exhibit a pop, rub, grunt, squeak, and/or creak noise from the front strut area during slow, lock-to-lock turns such as parking maneuvers. Vehicles built on or before 1/13/2009 may also exhibit a clunk, crunch, thump, and/or knocking noise from the front strut area while driving over a series of bumps and/or rough roads. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Using chassis ears on the front strut mounts is pop, rub, grunt, squeak, creak, clunk, crunch, thump, and/or knocking noise present from the front strut area during slow parking lot type maneuvers? a. No - Procedure does not apply, proceed with normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes on turns - Boot may be binding, go to Step 2 Dust Boot Greasing Procedure. c. Yes over bumps (built on or before 1/13/2009) - Go to Step 3 Dust Boot Replacement Procedure and install new dust boot designed for this concern. d. Yes over bumps (built after 1/13/09) - Procedure does not apply. Proceed with normal WSM, Section 204-00 diagnostics. 2. Dust Boot Greasing Procedure. a. Raise the vehicle per WSM, Section 100-02. b. Reach through the spring and pull the strut dust boot and jounce bumper assembly straight down, out of the upper spring seat. c. Apply Motorcraft(R) Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust cover. d. Raise dust cover so that jounce bumper is accessible and apply 360 degrees to the jounce bumper itself. e. Slide the dust cover and jounce bumper upward into its original location on the strut. f. Repeat the procedure on the other side of the vehicle. 3. Dust Boot Replacement Procedure (vehicles built on/before 1/13/2009). a. Remove front strut per WSM, Section 204-01. b. Disassemble front strut and replace dust boot with latest level part per WSM, Section 204-01. Page 7815 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. Locations View 151-14 (Under Dash Panel, LH Side) Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Worldwide Diagnostic System (WDS) Special Tool(s) Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). System Diagnosis P1633 Steering/Suspension - Control Arm Bushing Inspection Control Arm Bushing: Technical Service Bulletins Steering/Suspension - Control Arm Bushing Inspection TSB 09-5-1 03/23/09 LOWER CONTROL ARM BUSHING INSPECTION PROCEDURE FORD: 2001-2009 Escape 2005-2009 Escape Hybrid MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Many states and Canadian provinces require annual safety inspections which include the evaluation of suspension components. The information in this procedure is intended to assist the technician performing the inspection with specific criteria for 2001-2009 Escape and Mariner lower control arm (LCA) bushings and will prevent the unnecessary replacement of good components. ACTION Inspect according to the procedure below. INSPECTION PROCEDURE The LCA bushing is located at the rear of the front suspension lower control arm. The bushing is identified as number 1 of Figure 1. The control arm is mounted in the front subframe with bolts number 2 and number 3. The bushing is part of the LCA and cannot be serviced separately from the arm. Page 6460 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 7080 Page 6234 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 7622 Horn: 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 3745 Locations View 151-13 (Behind Dash Panel) Page 2657 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 7434 Symbols Part 2 Front Safety Belt Retractor Seat Belt Retractor: Service and Repair Front Safety Belt Retractor FRONT SAFETY BELT RETRACTOR Torx Bit, Safety Belt Bolt Special Tool(s) Removal and Installation WARNING: - All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies be installed unless a qualified technician Page 1831 To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Disconnect the high pressure cut-off switch electrical connector. 5. Remove the condenser to evaporator line bracket nut. - To install, tighten to 8 Nm (71 lb-in). 6. Disconnect the evaporator core spring lock coupling. 7. Remove the condenser to evaporator line peanut fitting nut and disconnect the line. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the condenser to evaporator line. 9. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Page 1170 Disclaimer Page 2977 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 4292 3. Using the special tool, support the engine. 4. Remove the 4 LH transaxle support insulator bolts. ^ To install, tighten to 55 Nm (41 ft. lbs.). 5. Remove the through-bolt and the LH transaxle support insulator. ^ To install, tighten to 90 Nm (66 ft. lbs.). 6. Remove the 3 nuts and the LH transaxle support insulator bracket. ^ To install, tighten to 90 Nm (66 ft. lbs.). 7. To install, reverse the removal procedure. Page 6748 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 3015 H2-H5 Page 8036 Locations View 151-19 (Center Console) Page 5044 Page 1828 Compressor Connection Page 2586 Page 4897 Page 4029 1. Install the manual control lever in the main control valve body. 2. NOTE: Inspect the solenoid valve body harness connector O-ring seal for damage. If damaged, install a new O-ring seal, before installing the connector into the case. Depress the retaining tabs and push the solenoid valve body electrical connector up through the transaxle case. 3. Position the main control valve body in place while connecting the manual valve link. 4. Install the main control valve body assembly. Tighten the bolts in the sequence indicated. ^ Tighten to 10 Nm (89 inch lbs.). Page 4245 Flywheel: Testing and Inspection Flywheel Inspection Flywheel Inspection 1. Inspect the flywheel for: 1. Any cracks. 2. Worn ring gear teeth. 3. Chipped or cracked ring gear teeth. Page 866 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the electrical connectors. 3. Remove the 2 screws and the parking aid module. 4. To install, reverse the removal procedure. Page 3893 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 1216 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 3663 Page 7233 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 2370 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 the 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 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Page 986 Page 3770 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. P1640 P1640 Service and Repair Backing Plate: Service and Repair Brake Backing Plate Removal and Installation 1. Remove the rear wheel cylinder. 2. Remove the jounce hose bracket bolt. ^ To install, tighten to 17 Nm (13 ft. lbs.). 3. Compress the parking brake cable conduit locking tabs and pull the parking brake cable assembly through the backing plate. 4. Remove the rear wheel hub. 5. Remove the 4 backing plate bolts and the backing plate. ^ To install, tighten to 66 Nm (49 ft. lbs.). 6. To install, reverse the removal procedure. Page 6441 Symbols Part 5 Locations View 151-13 (Behind Dash Panel) Testing and Inspection Micro ISO Relay: Testing and Inspection Page 2499 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. P0605 P0605 Page 1538 6. NOTE: Align the hood latch position as previously marked during removal. Install the hood latch assembly. 1 Position the hood latch. 2 Install the hood latch bolts. Tighten to 9 Nm (80 lb-in). 3 Tighten the hood latch nut. Tighten to 9 Nm (80 lb-in). 7. CAUTION: Make sure the hood latch is fully engaged. Verify the hood latch striker is fully engaging the hood latch. 8. Repower the system. Specifications Axle Nut: Specifications Wheel hub nut Tighten to ............................................................................................................................................. ........................................... 290 Nm (214 ft. lbs.) Page 7044 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. Page 5146 Disclaimer Page 3647 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. P0171 P0171 Page 829 P2258 Page 7800 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 4472 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. P1137 P1137 Page 6559 Front Door Latch: Service and Repair Front Door Latch FRONT DOOR LATCH Removal and Installation 1. Remove the exterior front door handle. 2. Loosen the exterior door handle reinforcement screw until the exterior door handle reinforcement slides free. 3. Release the interior door handle clip. 4. Remove the interior door handle. 1 Disconnect the cable conduit. 2 Disconnect the door latch cable. Page 4985 P1270 P1270 Page 5686 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 7840 Turn Signal Lamp: Service and Repair SIDE TURN SIGNAL LAMP Removal and Installation 1. Remove the side marker lamp. 1 Push the side marker lamp rearward. 2 Pull outward from the front of the side lamp and remove. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Diagrams Service and Repair Throttle Cable/Linkage: Service and Repair ACCELERATOR CABLE Page 5635 4. 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. 5. 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. 6. Remove and discard the evaporator core inlet line fitting O-ring. Installation 1. Lubricate the evaporator core orifice O-rings with clean mineral oil and install the evaporator core orifice using the special tool. 2. Connect the condenser to evaporator line spring lock coupling. 3. Install the condenser to evaporator line. Page 7557 Dimmer Switch: Testing and Inspection Page 39 P0104 Windshield Wiper Blade and Pivot Arm Adjustment Wiper Arm: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers 2. Verify that the RH and LH wiper blades are located at the specified position. 3. If not within specification, remove the nuts and the windshield wiper pivot arms and reposition them to the correct locations. - To install, tighten to 35 Nm (26 lb-ft). Page 4519 Locations View 151-7 (Engine, front) Page 6090 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 4384 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Page 2740 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. P1405 P1405 Locations View 151-11 (Manual Transmission) Page 6101 6. NOTE: Align the hood latch position as previously marked during removal. Install the hood latch assembly. 1 Position the hood latch. 2 Install the hood latch bolts. Tighten to 9 Nm (80 lb-in). 3 Tighten the hood latch nut. Tighten to 9 Nm (80 lb-in). 7. CAUTION: Make sure the hood latch is fully engaged. Verify the hood latch striker is fully engaging the hood latch. 8. Repower the system. Page 2303 Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Remove the throttle body. 3. Remove the fuel rail. 4. Remove the oil level indicator and tube. 5. Disconnect the intake manifold vacuum hose and pin-type retainer. ^ Position the vacuum hose aside. 6. Disconnect the power brake booster vacuum tube ^ Depress the quick release locking ring. ^ Pull the vacuum tube out of the quick release fitting. 7. Disconnect the fuel vapor return hose from the intake manifold. 8. Disconnect the idle air control(IAC) motor electrical connector. Page 5680 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Testing and Inspection Mini ISO Relay: Testing and Inspection Page 5975 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Instrument Cluster Bulb Instrument Panel Bulb: Service and Repair Instrument Cluster Bulb INSTRUMENT CLUSTER BULB Removal and Installation 1. Remove the instrument cluster. 2. NOTE: To remove the illumination bulb, rotate the bulb one quarter turn counterclockwise and lift it straight out from the instrument cluster. Remove the illumination bulb(s) in question. 3. To install, reverse the removal procedure. Page 5794 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Page 7027 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 2428 Coolant: Fluid Type Specifications Engine Coolant Type ......................................................................................................... Motorcraft Premium Gold Engine Coolant (yellow-colored) Page 6285 Symptom Chart (Part 5) Page 5594 Compressor Clutch Relay: Description and Operation AIR CONDITIONING CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. 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 communications network). 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 A/CCR output, closing the relay contacts and sending voltage to the A/C clutch. Page 4733 Page 1335 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 6494 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 1376 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 5462 Disclaimer Page 1486 Page 6049 finds the assemblies show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 passenger side safety belt retractor is shown, the driver side is similar. All front retractors 1. Remove the B-pillar trim panel. Front passenger retractor 2. Depower the SRS. 3. Disconnect the belt tension sensor electrical connector. All front retractors 4. Remove the safety belt retractor anchor bolt. - To install, tighten to 47 Nm (35 lb-ft). 5. Remove the safety belt retractor upper bolt. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the safety belt retractor lower bolt and the safety belt retractor. - To install, tighten to 47 Nm (35 lb-ft). 7. To install, reverse the removal procedure. Front passenger retractor 8. Repower the SRS. All front retractors 9. Check the active restraint system for correct operation. - Make sure that after the rear safety belt retractor is installed, the retractor is not in the automatic locking retractor (ALR) mode. Procedures Transmission Cooler: Procedures Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Flush with clean transmission fluid only. Do not use solvents, mineral spirits or water-based cleaners. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Backflush any contaminates out of the oil-to-air cooler by connecting the flushing machine pressure line to number 1 and the return line to number 2. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. 2. Backflush any contaminants out of the radiator in-tank cooler by connecting the flushing machine pressure line to number 2 and the return line to number 3. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. Page 4198 5. If reinstalling the original inner joint, mark the inner CV joint and the halfshaft to be sure of correct installation. 6. Using a soft face hammer, separate the halfshaft from the inner joint housing. 7. Remove and discard the bearing retainer circlip. 8. Remove and discard the snap ring. 9. Remove the inner halfshaft boot from the halfshaft. 10. Remove the 2 outer halfshaft boot clamps. 11. Slide the outer halfshaft joint boot back out of the way exposing the outer CV joint. 12. If reinstalling the original inner CV joint, mark the outer CV joint and the halfshaft to be sure of correct installation. 13. Using a soft-face hammer, separate the outer CV joint by gently tapping it off the halfshaft. 14. Remove and discard the bearing retainer circlip. 15. Remove the snap ring from the halfshaft. Locations View 151-14 (Under Dash Panel, LH Side) Locations View 151-7 (Engine, front) Page 6104 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar SIDE IMPACT SENSOR - SECOND ROW, C-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the C-pillar trim panel. 3. Remove the side impact sensor bolt. 4. Disconnect the electrical connector and remove the side impact sensor. Installation 1. Connect the electrical connector to the side impact sensor. Page 3459 3. 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: Carefully release the locking tabs to avoid breakage. Release the fuel tube-to-fuel rail quick release coupling primary locking tab. 4. Rotate the primary locking tab to the fully opened position and squeeze the secondary locking tabs to release the locking mechanism. 5. Push the locking mechanism outward and release the tube. 6. Disconnect the fuel rail pressure and temperature vacuum tube and electrical connector. 7. Disconnect the 4 fuel injector electrical connectors. 8. Remove the 2 fuel rail bolts and detach the wiring retainers from the fuel rail. 9. Remove the fuel rail and injectors as an assembly and then remove the spacers. 10. Remove the 4 fuel injector retainer clips and the fuel injectors. Page 4712 Page 2074 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 7235 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 3818 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Page 6008 Page 4026 5. Disconnect the transaxle wiring harness electrical connector and the Transmission Range (TR) sensor electrical connector. 6. Disconnect the shift cable. 7. Remove the shift cable and bracket and position it aside. 8. Remove the vent tube hose from the main control cover. Page 5665 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 were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose-to-heater core attachments. A coolant leak in the heater water 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-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Verify the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches a normal operating temperature, feel the heater core inlet and outlet hoses to see if they are hot. If the inlet hose is not hot: the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the pressure tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the pressure tester in the heater water hose ends. Secure the heater water hoses, the plug, and the adapter with hose clamps. 5. Attach the pump and gauge assembly from the pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform 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 water hoses with plug and adapter to the core tubes. Then connect the pressure tester to the adapter. Page 2249 5. Use the special tool to raise the engine 25 mm (0 98 inch). 6. Remove the 2 nuts and the engine mount bracket. ^ To install, tighten to 90 Nm (66 ft. lbs.). 7. Remove the 3 bolts and the engine mount. ^ To install, tighten to 55 Nm (41 ft. lbs.). 8. To install, reverse the removal procedure. Page 6426 Parts Block WARRANTY STATUS: Information Only Disclaimer Page 3122 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Page 770 P2068 Page 7712 Page 5180 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Window Adjust Switch Power Window Switch: Locations Window Adjust Switch View 151-23 (Right Front Door) Locations View 151-7 (Engine, front) Page 4225 10. If the runout measurement still exceeds the specification at the rear, mark the rear runout high point on the driveshaft. 11. If the runout measurement is within specifications, go to Step 13. 12. NOTE: Excessive driveshaft runout may originate in the driveshaft itself or in the axle pinion flange. Compare the two high points marked in Steps 6 and 10. ^ If the marks are within 25 mm (1 inch), then install a new driveshaft. ^ If the marks are not within 25 mm (1 inch), balance the driveshaft. Go to Step 13. 13. CAUTION: To prevent overheating, do not run the vehicle on the hoist for an extended period of time. Record baseline speed with the transmission in gear. ^ Increase the vehicle speed to the maximum vibration level. ^ Record the speed of the vibration as a baseline. 14. WARNING: Keep hands away from the balance weights while the driveshaft is rotating. Failure to follow these instructions may result in personal injury. With the transmission in gear, run the vehicle with the driveshaft rotating 97-113 km/h (60-70 mph). 15. WARNING: Keep hands away from the balance weights while the driveshaft is rotating. Failure to follow these instructions may result in personal injury. Have an assistant contact the driveshaft with a marker in the rear, middle and front end to indicate heavy spots. 16. WARNING: Keep hands away from the balance weights while the driveshaft is rotating. Failure to follow these instructions may result in personal injury. To balance the driveshaft, install two screw-type hose clamps on the driveshaft and rotate them in 90 degree intervals. Check the vibration for each position and place the screws at the position that produces the least vibration. 17. Run the vehicle at the baseline speed. 18. If the vibration is still evident, rotate the clamps away from each other until the driveshaft is balanced. Page 6335 Disclaimer P1233 P1233 Page 3548 Page 7694 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 2734 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity .............................................................................................................. ......................................................................... 12 oz. Page 5339 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Specifications Thermostat Housing: Specifications Thermostat housing bolts .................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Page 6314 C2-C4 Normal Operation The audio unit monitors the vehicle speed over circuit 679 (GY/BK). Possible Causes - circuit 679 (GY/BK) open or short to ground - anti-lock brake system (ABS) module - audio unit Test D: The Navigation System Does Not Operate Correctly - No Global Positioning System (GPS) Antenna Signal PINPOINT TEST D: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - NO GLOBAL POSITIONING SYSTEM (GPS) ANTENNA SIGNAL Page 4271 Shifter M/T: Service and Repair Gearshift Lever Boot Gearshift Lever Boot Removal and Installation CAUTION: The gearshift lever boot and gearshift lever knob is one assembly. 1. Separate the gearshift lever boot from the floor console. 2. NOTE: The gearshift lever boot has been removed for clarity. Cut the gearshift lever knob crimp ring. 3. Remove the gearshift lever knob and gearshift lever boot assembly. 4. CAUTION: A fully seated knob will conceal the knurled section on the gearshift lever. Failure to fully seat the gearshift knob may cause gearshift lever boot damage. To install, reverse the removal procedure. ^ Crimp the ring to 40 Nm (30 ft. lbs.). Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Page 2174 Inspect the crankshaft pulley for rubber protruding from the pulley (Figure 1), loose pulse wheel, or bent tabs on pulse wheel touching engine front cover. Replace crankshafl pulley with service kit for respective vehicle line. NOTE ESCAPE! MARINER HYBRID 2.3L ATK HEV ENGINE DOES REQUIRE THE SERVICE TOOLS BUT NO SERVICE KIT WAS RELEASED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062104A 2003-2007 Focus 2.3L 1.5 Hrs. PZEV 2005-2007 Focus 2.0L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A 2006-2007 Fusion/Milan 1.6 Hrs. 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A 2005-2007 Escape/Mariner 1.6 Hrs. 2005-2007 Escape Hybrid, Page 7326 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 5104 Alignment: Service and Repair Lean Correction Lean Correction NOTE: When installing a new coil spring, install a new spring with the same part number and the same spring code. Refer to the Vehicle Certification (VC) label on the driver's side door. 1. Measure the distance from the wheelhouse opening to the center of the wheel and tire at the same point on both sides of the vehicle. 2. If the difference exceeds 10 mm (0.4 inch), a lean correction is necessary. 3. Remove the higher side coil spring. 1 If the original coil spring exceeds the height of the new one by 10 mm (0.4 inch), install the new coil spring in the vehicle. 2 If the original coil spring is shorter than the new one by 10 mm (0.4 inch), remove the low side coil spring from the vehicle. 4. Compare all 3 coil springs and select the 2 most evenly matched for installation. Page 4918 Disclaimer Page 7632 Horn: 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 Page 1303 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... .......................................................... 2.95 pts. (1.4L) Coil On Plug (COP) Ignition Coil: Description and Operation Coil On Plug (COP) COIL ON PLUG (COP) The COP ignition operates similar to standard coil pack ignition except each plug has one coil per plug. COP has 3 different modes of operation: engine crank, engine running, and CMP Failure Mode Effects Management (FMEM). Page 7868 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 Page 6497 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 2196 4. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. ^ The hole in the crankshaft pulley should be in the 6 o'clock position. 5. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage. NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the special tool in the slots on the rear of both camshafts. 6. Remove the engine plug bolt. Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 6281 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Page 5199 4. Remove the 3 bolts and the rear transaxle mounting plate. ^ To install, tighten to 90 Nm (66 ft. lbs.). 5. NOTE: Do not loosen the tie-rod end nut to align the slot in the nut with the tie-rod end stud through-hole. Remove the 2 outer tie-rod end cotter pins and the 2 tie-rod end nuts. ^ To install, tighten to 55 Nm (41 ft. lbs.). ^ If necessary, continue to tighten the tie-rod end nut until the slot in the nut aligns with the tie-rod end stud through-hole. 6. Using the special tool, separate the tie-rod end from the knuckle. 7. 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. Refer to Air Bag Systems. Hold the steering wheel in a straight-ahead position using a suitable tool. 8. Remove the nuts and the steering column boot. 9. Remove the steering column coupling-to-steering gear pinch bolt. ^ To install, tighten to 40 Nm (30 ft. lbs.). 10. Remove the steering gear-to-fluid cooler return hose bracket-to-subframe bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 11. Remove the power steering pressure line bracket-to-steering gear bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 12. Remove the steering gear-to-fluid return hose bracket-to-steering gear stud. ^ To install, tighten to 10 Nm (89 inch lbs.). 13. Remove the power steering line clamp plate bolt. ^ To install, tighten to 25 Nm (18 ft. lbs.). Page 4014 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 1590 Seat Sensor/Switch: Locations Seat Belt Buckle Sensor View 151-20 (Driver Seat) Locations View 151-7 (Engine, front) Page 7731 Page 3989 6. Install the LH splash shield and the 7 retainers. ^ Tighten to 10 Nm (89 inch lbs.). 7. Install the LH splash shield. Diagrams Locations View 151-19 (Center Console) Page 6046 Seat Belt Retractor: Description and Operation Safety Belt Retractor Pretensioner - Escape Hybrid The Escape Hybrid driver safety belt retractor uses a safety belt pretensioner system. This works in conjunction with the safety belt buckle pretensioner, front air bag system and, if equipped, side air bag system. The pretensioner is a pyrotechnic device that removes excess webbing slack from the safety belt. When activated by the restraints control module (RCM), the pretensioner deploys in the retractor, removing excess slack from the lap and shoulder safety belt. The pretensioners are activated when the RCM detects an impact force exceeding a programmed limit. 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. For safety belt retractor pretensioner diagnostic information, refer to Air Bag Systems. For safety belt retractor pretensioner disposal information, refer to Air Bag Systems. 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, 3-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 disengaged when the webbing is free to move in or out of the retractor. 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 that the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. 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 4083 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. Locations View 151-8 (Engine, rear) Safety Belt Buckle and Pretensioner Seat Belt Buckle: Service and Repair Safety Belt Buckle and Pretensioner SAFETY BELT BUCKLE AND PRETENSIONER Torx Bit, Safety Belt Bolt Special Tool(s) Removal and Installation WARNING: - All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 Page 4027 9. Remove the splash shield. 10. Remove the transaxle drain plug and drain the transmission fluid. 11. Remove the main control cover bolts, studs and the cover. 12. NOTE: Do not discard the gasket. It is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary. Remove the main control cover gasket. Output Shaft Speed (OSS) Sensor Tires - Vibration Highway at Speeds Tires: Customer Interest Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 3131 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 2812 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Page 5841 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The 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 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. 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 carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC if a SRS fault exists. The air bag indicator will flash the LFC 5 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, to the diagnostic 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 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides 150 ms of backup power to deploy the front air bags and pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Locations Page 2544 Removal 1. Remove the exhaust flexible pipe. 2. Remove the 2 catalytic converter bracket bolts. 3. Remove the 6 heat shield bolts and the heat shield. Locations View 151-7 (Engine, front) Page 193 P0277 Page 5183 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 5113 Power Steering Pressure Switch: Diagrams Page 3123 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 1374 Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Power Steering Pump-2.3L Special Tool(s) Material Heated Oxygen Sensor (HO2S) #22 Page 946 Service and Repair Hood Latch Release: Service and Repair HOOD LATCH RELEASE HANDLE Removal and Installation 1. Remove the hood latch. 2. Remove the 3 hood latch release handle cable locators. 3. Remove the 2 hood latch release handle screws. - To install, tighten to 6 Nm (53 lb-in). 4. NOTE: The hood latch release handle and cable assembly must be pulled through the dash panel into the passenger compartment. Remove the hood latch release handle and cable assembly. 5. To install, reverse the removal procedure. Page 7927 Page 1676 Page 1362 Fuel Level Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 5969 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 1997 Page 3496 Mechanical Returnless Fuel Pump Module (FPM) Locations View 151-13 (Behind Dash Panel) Page 1861 ^ Plug the clutch master cylinder feed hose. 5. Remove the reservoir. ^ Release the retaining clips on the underside of the reservoir. ^ Pull the reservoir upwards. 6. NOTE: Install new seals. Lubricate the seals with clean DOT 3 motor vehicle brake fluid. Remove and discard the 2 seals. 7. To install, reverse the removal procedure. ^ Bleed the brake system. ^ If equipped with a manual transmission, bleed the clutch master cylinder. Page 6236 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 3469 14. Unclip the fuel tube retainer clip from the mounting stud to service the fuel supply and vapor tubes as an assembly. The retainer clip will also open to service the tubes individually. Remove the fuel supply and fuel vapor tubes from the vehicle. Installation 1. Install the fuel supply tube and fuel vapor tubes. - Make sure the retainer clips snap into place when installing onto the studs. Pull on the clips to make sure they are correctly seated. 2. NOTE: Make sure the tubes are correctly snapped into the clip and the clip is snapped securely into the subframe. Install the fuel supply and fuel vapor tubes into the frame-mounted retainer clips. 3. NOTE: - Make sure the collar on the fuel tube is inserted fully into the quick connect coupling before the locking tab is locked. - Apply clean engine oil to the end of the tube before inserting a tube into the connector. Connect the fuel supply jumper tube and the fuel vapor tube quick connect couplings. 1 Connect the quick connect couplings. 2 Press the quick connect coupling locking tabs into position. Pull on the fittings to make sure they are fully engaged. 4. NOTE: - Make sure the collar on the fuel tube is inserted fully into the quick connect coupling before the locking tab is locked. - Apply clean engine oil to the end of the tube before inserting a tube into the connector. Connect the fuel vapor tube quick connect coupling to the EVAP canister purge valve. 1 Connect the quick connect couplings to the EVAP canister purge valve. Page 5061 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) Locations View 151-12 (Dash Panel) Page 2185 1. CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage. Use tool suitable to seat the expansion-type cylinder block core plug. Page 309 P0463 Refrigerant Discharging and Recovery Procedure Refrigerant: Service and Repair Refrigerant Discharging and Recovery Procedure AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Recovery NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Locations View 151-13 (Behind Dash Panel) Page 7637 B1217-B1218 Page 7625 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 Fuel Pump Module and Reservoir Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 4030 5. NOTE: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary. Install the main control cover gasket. 6. NOTE: Install the cooler bypass valve studs in locations 3 and 11. Install the main control cover. Tighten the bolts and studs in the indicated sequence. ^ Tighten to 13 Nm (10 ft. lbs.). 7. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Page 1146 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may result in personal injury. - The seat 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the seat control switch knob. 4. Remove the 3 screws and the outboard front seat side cushion shield. - If equipped, disconnect the heated seat switch electrical connector. - Disconnect the seat control switch electrical connector. 5. Remove the 3 seat control switch screws. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. 7. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Parking Aid Sensor, Outer Left View 151-15 (Full Body, Left Rear - 1 Of 2) Page 1703 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer Liftgate Ajar Switch View 151-25 (Liftgate) Page 3391 Air Flow Meter/Sensor: Diagrams A/T - Shifter Release Button Cap Falls Off Shifter A/T: Customer Interest A/T - Shifter Release Button Cap Falls Off TSB 05-4-5 03/07/05 SHIFTER RELEASE BUTTON CAP FALLS OFF FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Mariner and Escape Hybrid vehicles may exhibit a loose gear selector button cap. The button cap may fall off, and will not stay in place when re-seated. ACTION Replace the gear selector button cap only, it is not necessary to replace the entire gear selector lever. For additional information, see the latest Escape/Mariner Workshop Manual CD, Section 307-05 Selector Lever Button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050405A 2005 Escape/Escape 0.2 Hr. Hybrid/Mariner: Replace Shifter Button DEALER CODING CONDITION BASIC PART NO. CODE 7C488 33 Disclaimer Page 4984 Page 7262 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Smart Junction Box Fuse Block: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Page 7453 B1342-C1789 Page 3114 Air Flow Meter/Sensor: Diagrams Page 6712 Front Subframe: Service and Repair FRONT SUBFRAME Special Tool(S) Special Tool(s) Connector Views Page 2924 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Page 4471 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 7403 Page 3823 Adding Fluid CAUTION: The use of any other type of transmission fluid than specified could result in transmission malfunction and/or damage. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. Before adding fluid be sure that the correct type is being used. The type of fluid that should be used is found on the fluid level indicator, on the handle, in the owner's manual, and in the Specifications. If fluid needs to be added, add fluid in 0.25L (1/2 pint) increments through the filler tube. Do not overfill the fluid. 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. 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 transmission. The engine cooling system should also be inspected at this time. 6. If fluid contamination or transmission failure is confirmed by the sediment in the bottom of the transmission fluid pan, the transmission must be disassembled and completely cleaned. This includes the torque converter and cooler lines. 7. Carry out diagnostic checks and adjustments. Page 7630 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 153 P0219 Page 4580 Brake Rotor/Disc: Specifications Brake Rotor/Disc Specifications Front Minimum thickness (disc-drum system) ......................................................................................................................................... 22 mm (0.86 inch) Minimum thickness to machine (disc-drum system) ................................................................................................................... 22.6 mm (0.88 inch) Minimum thickness (4-wheel disc brake system) .......................................................................................................................... 24 mm (0.95 inch) Minimum thickness to machine (4-wheel disc brake system) ..................................................................................................... 24.6 mm (0.97 inch) Rear Minimum thickness .............................................................................................................................. ........................................ 11.0 mm (0.43 inch) Minimum thickness to machine ................................................................................................................................................... 11.6 mm (0.45 inch) Page 8013 Wiper Arm: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper. 2. Verify that the rear window wiper blade is located at the specified position. 3. If not within specification, remove the rear window wiper pivot arm and reposition it to the correct location. Page 1398 Oxygen Sensor: Harness Locations View 151-8 (Engine, rear) Page 6868 19. CAUTION: Do not disconnect the delete resistor during headliner removal. If equipped, cut and remove the lanyard between the delete resistor and the headliner. 20. Remove the headliner. 21. To install, reverse the removal procedure. Page 1580 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 electronic control unit (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 OEM OCS, refer to the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Page 5048 Page 6697 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 5461 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 5825 10. If the vehicle is equipped with a moonroof, connect the moonroof rear drain hose. 11. Connect the safety canopy module electrical connector and attach the connector to the D-pillar. 12. Install the safety canopy module wiring clip to the roof panel brace. 13. Install the remaining 2 safety canopy module bolts near the ignitor (between the C and D-pillars). - Tighten to 8 Nm (71 lb-in). 14. Install the headliner. 15. Repower the system. P1516 P1516 Page 1949 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ........................................................................................................................ PAG Refrigerant Compressor Oil (R134a Systems) * Meeting Ford Specification WSH-M1C231-B Service and Repair Coolant Reservoir: Service and Repair Degas Bottle Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Disconnect the radiator-to-degas bottle hose from the degas bottle. 2.3L vehicles 4. Disconnect the degas bottle-to-coolant bypass housing hose. All vehicles 5. Remove the 2 degas bottle nuts. ^ To install, tighten to 6 Nm (53 inch lbs.). 6. Lift the degas bottle up and disconnect the degas bottle-to-radiator hose. ^ Remove the degas bottle. Page 3196 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the HO2S. To install, tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensor. To install, reverse the removal procedure. Electrical - Wiring Harness Replacement Guidelines Wiring Harness: 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 1575 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 7. Remove the seat cushion foam pad. 8. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 9. CAUTION: Care must be taken to prevent damage to the set cushion pan when removing the rivets. Remove the 2 rivets and the OCS ECU. 10. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 11. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. See: Occupant Classification Sensor - Service Kit 1. Bend the retaining tab back on the pressure sensor component bracket. Page 6472 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 538 P1266 Page 1020 2. Remove the lower LH center instrument panel finish panel. 3. Position back the carpet on the LH and RH tunnel to access the RCM. 4. Disconnect the large 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 large RCM electrical connector. 5. Disconnect the small RCM electrical connector. 6. Remove the 3 bolts and the RCM. Installation Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. P0400 P0400 Page 7444 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 200 P0283 Service and Repair Trunk / Liftgate Handle: Service and Repair LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Service and Repair Auxiliary Step / Running Board: Service and Repair RUNNING BOARD Removal and Installation 1. Remove the 6 running board bolts. - To install, tighten to 25 Nm (18 lb-ft). 2. Remove the running board. 3. Remove the 6 running board support bracket bolts and the 3 running board support brackets. - To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Page 599 P1409 Heated Oxygen Sensor (HO2S) #22 Heated Oxygen Sensor (HO2S) #22 Page 1258 Fuel Gauge Sender: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 3759 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 1851 Removal and Installation All vehicles CAUTION: While 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. NOTE: New O-rings must be installed any time the lines are disconnected from the steering gear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the power steering fluid into a suitable drain pan. 3. Remove the power steering pressure line fitting nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) (2.3L engine). ^ To install, tighten to 73 Nm (54 ft. lbs.) [3.0L (4V) engine]. 4. Remove the power steering pressure line bracket nut. ^ To install, tighten to 10 Nm (89 inch lbs.) (2.3L engine). ^ To install, tighten to 12 Nm (9 ft. lbs.) [3.0L (4V) engine]. 3.0L (4V) only 5. Disconnect the Power Steering Pressure (PSP) switch electrical connector. All vehicles 6. Remove the power steering pressure line bracket-to-steering gear bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Remove the power steering line clamp plate bolt. ^ To install, tighten to 25 Nm (18 ft. lbs.). 8. NOTE: The power steering pressure and return lines are of different diameters and the O-rings are not interchangeable. Rotate the clamp plate and remove the power steering pump-to-steering gear pressure line. ^ Install a new high pressure line O-ring. 9. To install, reverse the removal procedure. 10. Fill the power steering system. Page 5819 5. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the deployment door. Through the glove box opening, push up to release the 3 lower deployment door clips (2 shown) from the instrument panel and push the lower end of the passenger air bag module out of the instrument panel, so the clips do not engage again. 6. Push down at the top of the deployment door, release the 3 clips and remove the passenger air bag module. Installation 1. NOTE: Make sure the J-clips are in place before positioning the passenger air bag module to the instrument panel. Install the passenger air bag module trim cover into the instrument panel. With the alignment pins positioned to the instrument panel, push in, seating the top (top shown) and bottom deployment door retainers. 2. Install the 4 passenger air bag module bolts. - Tighten to 8 Nm (71 lb-in). 3. Connect the passenger air bag module electrical connector. 4. Close the glove compartment door. 5. Repower the system. Page 5970 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Page 7947 4. NOTE: - Lubricate the urethane adhesive with water to aid the special tool when cutting. - Locating pins need to be cut through in order to remove the rear quarter window glass. The new quarter window glass will be equipped with new locating pins. Using the special tool, cut the urethane adhesive from the quarter window glass starting at the top center and working toward the bottom corners and remove the rear quarter window glass. 5. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. Installation All Rear Quarter Window Glass CAUTION: After installing the urethane installed 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 temperatures and humidity vary.) Inadequate curing of the urethane adhesive will adversely affect the strength of the urethane bond. 1. Dry fit the rear quarter window glass, making alignment marks with tape or non-staining grease pencil. 2. CAUTION: Do not scratch the pinch weld area. Trim the remaining urethane adhesive on the pinch weld to the specification. The existing urethane adhesive surface should be smooth and free of cuts and contamination. 3. CAUTION: Use caution when applying metal primer. Apply a light amount of primer. Too much primer will run and damage the painted surface. Use a wool applicator to apply metal primer to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. Clean the inside of the rear quarter window glass surface with alcohol-free cleaner, making sure the ceramic coated area is clean. 5. CAUTION: If installing a LH rear quarter window on the Escape Hybrid, do not apply urethane glass prep to the polycarbonate vent of the window assembly. NOTE: Wipe off the glass prep immediately after each application because it flash dries. Apply glass prep twice around the glass surface to be urethaned. Page 3998 Page 1758 1. Inspect the spark plugs. 2. Adjust the spark plug gap as necessary. 3. Install the spark plugs. - Tighten to 12 Nm (9 lb-ft). 4. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Install the ignition coils and bolts. Tighten to 10 Nm (89 lb-in). 5. Connect the ignition coil electrical connectors. 6. Connect the battery ground cable. Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS Removal and Installation 1. Open the liftgate window glass. 2. Remove the 2 liftgate window glass nut access covers. Page 4129 Shifter CVT: Service and Repair Selector Lever Knob Selector Lever Knob Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Disconnect the overdrive cancel switch electrical connector. Page 2934 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the powertrain control module (PCM) stud bolt nut and position the wiring harness aside. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the 3 PCM electrical connectors. 4. Remove the stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the PCM cowl seal. 6. To install, reverse the removal procedure. Page 2682 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Page 7301 C5-C6 Normal Operation The instrument cluster sends a signal to the message center INFO switch on circuit 1411 (GY/OG), and to the message center SET switch on circuit 1410 (TN/OG), which communicates the requested switch function to the message center. The switches are grounded through circuit 570 (BK/WH). Possible Causes - circuit 570 (BK/WH) open - circuit 1411 (GY/OG) open or short to ground - circuit 1410 (TN/OG) open or short to ground - message center SET switch - message center INFO switch - instrument cluster Test D: The Compass Is Inoperative PINPOINT TEST D: THE COMPASS IS INOPERATIVE D1 Page 5928 event of an air bag deployment. - Inspect the seat side air bag deployment chute and the seat 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. - If the air bag deployment chute is not properly positioned, the side air bag may not deploy properly. - If the air bag cover has separated or the air bag material has been exposed, install a new side air bag module. Do not attempt to repair the air bag module. Failure to do so may result in personal injury in the event of an air bag deployment. CAUTION: Make sure the side air bag module wiring harness is not pinched between the side air bag module and the mounting bracket. All seats 1. Install the side air bag module and nuts onto the seat backrest frame mounting bracket. - To install, tighten to 5 Nm (44 lb-in). 2. Attach the 2 side air bag module wiring harness retainers to the seat backrest frame. 3. Roll down the seat trim cover to the side air bag module. 4. WARNING: Check the side air bag deployment chute for damage. The deployment chute must not be repaired. If there is any damage to the deployment chute, the seat back trim cover and deployment chute must be installed new as a unit. Feed the side air bag module deployment chute, J-clips, and hook and loop retainer back through the side air bag module seat back foam opening. Description and Operation Air Diverter Solenoid: Description and Operation Secondary Air Injection Bypass Solenoid For information on the secondary air injection bypass solenoid, refer to the description of the Secondary Air Injection (AIR) Systems. Page 408 P0723 Page 127 P0183 Page 5155 Removal and Installation All vehicles CAUTION: While 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. NOTE: New O-rings must be installed any time the lines are disconnected from the steering gear. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the power steering fluid into a suitable drain pan. 3. Remove the power steering pressure line fitting nut. ^ To install, tighten to 65 Nm (48 ft. lbs.) (2.3L engine). ^ To install, tighten to 73 Nm (54 ft. lbs.) [3.0L (4V) engine]. 4. Remove the power steering pressure line bracket nut. ^ To install, tighten to 10 Nm (89 inch lbs.) (2.3L engine). ^ To install, tighten to 12 Nm (9 ft. lbs.) [3.0L (4V) engine]. 3.0L (4V) only 5. Disconnect the Power Steering Pressure (PSP) switch electrical connector. All vehicles 6. Remove the power steering pressure line bracket-to-steering gear bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Remove the power steering line clamp plate bolt. ^ To install, tighten to 25 Nm (18 ft. lbs.). 8. NOTE: The power steering pressure and return lines are of different diameters and the O-rings are not interchangeable. Rotate the clamp plate and remove the power steering pump-to-steering gear pressure line. ^ Install a new high pressure line O-ring. 9. To install, reverse the removal procedure. 10. Fill the power steering system. Fuel System - Slow Fuel Fill/MIL ON/DTC P0451 Fuel Tank Vent: Customer Interest Fuel System - Slow Fuel Fill/MIL ON/DTC P0451 TSB 08-5-5 03/17/08 SLOW FUEL FILL AND/OR DTC P0451 FORD: 2005-2008 Escape Hybrid, Escape MERCURY: 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 07-25-7 to update the Title and Service Procedure. ISSUE Some 2005-2008 Escape, Escape Hybrid, Mariner and 2006-2008 Mariner Hybrid vehicles may exhibit a slow fuel fill concern or a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0451 present. The condition may be caused by water/moisture or other contamination entering the fuel filler vent line and then freezing and/or causing a blockage. ACTION Follow the Service Procedure steps to correct the condition by relocating the fuel filler vent line. SERVICE PROCEDURE When performing this procedure it is not necessary to: ^ Drain any fuel from the tank ^ Remove the stone shield from the filler pipe ^ Disconnect the filler pipe from the fuel tank NOTE ANY WATER/MOISTURE OR OBSTRUCTIONS IN THE EVAPORATIVE VENT SYSTEM MUST BE REMOVED. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the left rear wheel. 3. Remove the fuel filler cap. 4. Remove the two (2) upper filler pipe mounting screws. 5. Remove the single lower filler pipe mounting screw. 6. Carefully pull the upper end of the filler pipe away from the inner wheel well to gain access to the vent line. 7. Cut any tape or plastic straps holding the black plastic convoluted vent line to the filler pipe or underbody. 8. Pull the black plastic convoluted vent line underneath the vehicle. 9. Remove the vent line from the dust separator attached to the canister assembly and clear out the line using compressed air. 10. Inspect the dust separator for water/moisture or any obstruction. If water/moisture or obstructions are present follow Workshop Manual (WSM), Section 310-00 pinpoint test A. If no water/moisture or obstructions are present reattach vent line to dust separator and continue to next step. 11. Remove but do not discard the spider screen (vent cap) from the end of the vent line. 12. Measuring from the open end of the vent line, cut off and discard the last 13" (35 cm). 13. Reinstall the spider screen (vent cap) in the vent line. Page 531 P1262 Page 7706 Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER Escape Is Shown, Mariner Is Similar (Part 1) Tires - Vibration Highway at Speeds Wheels: Customer Interest Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 1765 2. If compression does not improve, valves are sticking or not seating correctly. 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 3151 Mechanical Returnless Fuel Pump Module (FPM) Page 2520 Page 2686 Page 2766 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Specifications Flywheel: Specifications ^ NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flywheel and tighten the bolts in the sequence shown in 3 stages. ^ Stage 1: Tighten to .............................................................................................................................. ..................................... 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten to ........................................................................................................................... ........................................ 80 Nm (50 ft. lbs.). ^ Stage 3: Tighten to ........................................................................................................................... ...................................... 112 Nm (83 ft. lbs.). Page 5391 Toe-In Can Be Claimed With Operation B And C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 18A179 07 Disclaimer Page 7215 Audible Warning Device: 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. 66-1 Page 652 P1513 Liftgate Ajar Switch View 151-25 (Liftgate) Page 7054 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the outboard front seat side cushion shield. - If removing the outboard passenger seat side cushion shield, remove the 2 screws and slide the shield forward. Disconnect the heated seat switch electrical connector. - If removing the driver seat side cushion shield, remove the 3 screws. Disconnect the heated seat switch electrical connector. - If equipped, disconnect the seat control switch electrical connector. 4. Remove the heated seat switch. 5. To install, reverse the removal procedure. 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) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Page 3683 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Page 6484 Y4-Y5 Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Brake Pedal Position (BPP) Switch Brake Signal: Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 2744 Page 4785 Starter Relay: Testing and Inspection P0297 P0297 Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 1328 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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 5060 Disclaimer Page 3937 5. Tighten the cable adjustment ring by turning it clockwise 1⁄4 turn. 6. Rotate the Z-bracket clockwise over the shift cable end fitting. ^ Tighten to 9 Nm (80 inch lbs.). Page 5344 3. Remove the 4 bolts and position the 4 rear control arms aside. 4. Remove and discard the exhaust hanger from the subframe. 5. With an assistant, remove the 4 bolts and the rear subframe. Installation All vehicles 1. With an assistant, position the rear subframe and install the bolts. - To install, tighten to 115 Nm (85 lb-ft). 2. Install a new exhaust hanger on the subframe. 3. NOTE: The vehicle must be at ride height before tightening the bolts. Position the 4 rear control arms into the subframe. Loosely install the bolts. Vehicles with 4WD 4. Install the rear axle assembly. All vehicles 5. Tighten the 4 rear control arms bolts. - Tighten to 115 Nm (85 lb-ft). Diagrams Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. System Diagnosis P061F Page 3713 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 3808 CAUTION: Do not use a screwdriver to remove the retaining ring or damage to the case may occur. Use only snap ring pliers to remove the retaining ring. Using the special tool, remove the servo retaining ring. 1 Install the special tool. 2 Compress the servo assembly by tightening the bolt. 3 Remove the retaining ring. 5. Remove the servo cover assembly. 6. Remove the intermediate and overdrive servo piston and return spring. 7. Wipe the servo piston and the servo cover cap with a lint free cloth. 8. CAUTION: Do not clean the rubber sealing surfaces of the servo piston and the servo cover cap with cleaning solvent or damage to the sealing surface may result. Inspect the servo piston for cracks on its pressure surfaces and in the sealing area. Look for damage near the point where the servo piston is attached to the servo rod. 9. Squeeze the servo piston lip for flexibility. If the lip feels brittle, install a new piston. 10. Inspect the servo retainer spring for cracks, breaks or deformation. Installation 1. Install the return spring and the intermediate overdrive servo piston. 2. Install the servo cover cap. 3. Install the special tool. 4. CAUTION: Do not use a screwdriver to install the retaining ring or damage to the case may occur. Use only snap ring pliers to install the retaining ring. NOTE: If the servo cover will not seat deep enough in the bore to install the servo cover retaining ring, use a blunt punch or small hammer and gently tap the cover around the outer edge until the servo cover retaining ring can be installed. Tighten the special tool bolt. ^ Install the servo cover retaining ring. 5. If the case is stamped WG, install a wide-groove snap ring, or the servo will be damaged. Page 7089 Page 7654 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 6736 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 7261 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Locations View 151-8 (Engine, rear) Service and Repair Seals and Gaskets: Service and Repair Halfshaft Oil Seal Special Tool(s) Removal and Installation CAUTION: New halfshaft oil seals should be installed anytime the halfshafts are removed. Failure to install new halfshafts seals may result in transmission oil leak(s). NOTE: RH intermediate shaft oil seal shown; LH halfshaft oil seal similar. 1. Remove the RH intermediate shaft or LH halfshaft. 2. Remove the RH intermediate shaft oil seal or the LH halfshaft oil seal. Installation Page 1174 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 6911 Page 341 P0538 Page 2383 Exploded View Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the air cleaner intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Page 3052 Oxygen Sensor: Harness Locations View 151-8 (Engine, rear) Page 4820 Page 1327 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Specifications Valve Clearance: Specifications NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. If any tappets do not measure within specifications, install new tappets in these locations. Right/Left Front View 151-3 (Engine Compartment, 1 Of 2) System Diagnosis P1489 Locations View 151-8 (Engine, rear) Page 7322 6. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The front impact severity sensor is located on the radiator support bracket. The first row side impact sensors (if equipped) are located at or near the base of the B-pillars. The second row side impact sensors (if equipped) are located on 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. 7. Remove the steering wheel access cover. 8. Disconnect the driver air bag module electrical connector. 1 Through the steering wheel access cover opening, release the pin-type retainer and slide the driver air bag module electrical connector off of the pin-type retainer. 2 Release the tab and disconnect the driver air bag module electrical connector. 9. Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column. Page 7507 Courtesy Lamp: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Page 659 P1519 Specifications Valve Cover: Specifications Valve Cover Tighten in the sequence shown to .............................................................................................................................................. 10 Nm (89 inch lbs.). Page 4919 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 4653 To assemble, reverse the disassembly procedure. Page 6846 1. Without pulling the headliner down beyond its natural hanging rest position, carefully inspect the structural foam blocks mounted at the passenger and drivers side front corners on the top of the headliner to see if they have one (1) or two (2) indentations. See Figure 2. ^ If the blocks have only one (1) indentation, proceed to DISASSEMBLY FOR MODIFICATION. ^ If the blocks have two (2) indentations, no modification is required. Proceed to ASSEMBLY. DISASSEMBLY FOR MODIFICATION 1. Remove the interior lamp lens. 2. Remove the two (2) screws and the interior lamp, then disconnect the electrical connector. 3. Proceed to STRUCTURAL FOAM BLOCK MODIFICATION. STRUCTURAL FOAM BLOCK MODIFICATION 1. Using fender covers, seat covers or suitable rags, cover the defroster and instrument panel ducts so chips cannot fall into the heater plenum while drilling. 2. Install a drill stop or apply suitable tape onto the drill bit 140 mm (5-1/2 in) from the end of the cutting portion of the bit (not from the threaded tip). See Figure 3. 3. CAUTION: The weight of the tool when positioned on the foam block increases the risk of headliner damage. Hold the headliner up when the tool is positioned on the foam block. Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: 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 4 to 8 seconds with no chime. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver's 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 Seat Belt Systems. Page 903 Page 5575 7. Using the special tool, install the A/C clutch bolt. - Tighten to 13 Nm (10 lb-ft). 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Page 7673 92-2 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 6945 View 151-21 (Passenger Seat) Locations View 151-13 (Behind Dash Panel) Page 4000 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 6166 Page 3956 12650D) 070506A 2005-2008 Escape/Mariner 5.8 Hrs. 4X4 2.3L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) 070506A 2005-2008 Escape/Mariner 5.9 Hrs. 4X2 3.0L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) 070506A 2005-2008 Escape/Mariner 7.5 Hrs. 4X4 3.0L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7902 30 Disclaimer P0830 P0830 Page 3258 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 the 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 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Heated Oxygen Sensor (HO2S) #22 Page 451 P1001 Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 2894 Camshaft Position Sensor: Diagrams Page 1312 Headlamp Switch: Testing and Inspection Page 7799 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 1952 4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant injector between the low-side gauge port valve and the refrigerant station or manifold gauge set. 6. Open all the valves and charge the refrigerant system. P1650 P1650 Page 1527 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 5904 Page 7287 to show the status of an event that has just happened and disappears after a few seconds. The warning display interrupts the current display until cleared or reset by the driver. Message Center General Displays The message center display is a 2 row by 12 character LCD display. The display is controlled by a 2 button switch module that includes INFO and SET buttons outside of the instrument cluster. The information displayed in the message center display falls into 4 main categories: jump start mode - info - warnings - temporary alerts Message Center Information Displays The INFORMATION DISPLAY mode is entered by pressing the INFO button. Subsequent presses of the INFO button scroll through the menu features of the information display. System Check When the SET FOR SYSTEM CHECK information is currently displayed, pressing the SET button leads the instrument cluster to initiate the system check function. The system check function provides the driver with the current status of certain vehicle functions. The status of each function is displayed sequentially on the message center. The driver has the ability to scroll through the system check displays by repeatedly pressing the SET button, or the display automatically scrolls at 2 seconds time out per display. The system check function can be terminated at any time by pressing any message center switch other than the SET button. Warning Indicators and Messages Warning Indicators And Messages The warning messages have precedence over all other messages. Every warning message is displayed. The messages can be single cycle, non-resettable, or repetitive. The instrument cluster indicators that are illuminated when a fault occurs and the message that follows are shown in the table. Warning Messages The instrument cluster messages that are displayed when a fault occurs are shown in the table. The warning messages continue to cycle in order until the vehicle condition causing the warning is corrected, until the ignition switch is turned to the OFF position, or until the message center is reset while the warning is displayed. A warning is removed from the display when the message center is reset unless the warning is non-resettable. A repeated warning message is removed from the display when the message center is reset and displays again after 10 minutes if the warning condition is not corrected. The single cycle warning message is removed from the display when the message center is reset and is not displayed again until the next ignition cycle. Multiple messages are cycled through in a fixed order with a display of 4 seconds for each warning. No other display modes are allowed while a warning message is displayed. Inspection and Verification Page 3149 Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 6804 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Page 1631 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 6276 The warning messages can interrupt the display until cleared or reset by the driver. The warning messages are either single cycle, non-resettable, or repetitive warning messages. The single cycle warning messages display once whenever the ignition switch is turned to the ON position or a fault occurs in a system, and can be cleared by pressing the RESET button. The single cycle warning messages are: liftgate ajar - liftgate glass ajar - service emission system - low brake fluid - service brake system - check left headlamp - check right headlamp - check left turn lamps - check right turn lamps - check left high beam - check right high beam - check brake lamps - check parking lamps - washer fluid low - check fuel cap - change oil soon - change oil now - low fuel - service 4x4 - turn signal on The repetitive warning message (park brake ON) displays whenever the ignition switch is turned to the ON position or a fault occurs in a system. The repetitive warning message appears again after a 10-minute interval until the condition is corrected. The non-resettable warning messages display whenever the ignition switch is turned to the ON position 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: high engine temperature - driver door ajar - passenger door ajar - driver rear door ajar - passenger rear door ajar Temporary Alert Messages The temporary alert display interrupts the current display to show the status of an event that has just happened. The temporary alert messages are: 4x4 locked temporarily - 4x4 disabled temporarily - 4x4 auto restored PRINCIPLES OF OPERATION - ESCAPE HYBRID The message center electronic functions use both hardwired and CAN circuits to receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - which module controls the output of the feature. Display Information The display modes are: information - setup - system check - warning - temporary alert Various message center information can be selected and reset by pressing the following buttons: SET - INFO The select display and the reset display time-out and default to the information display mode. The temporary alert display interrupts the current display 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 3920 Shifter A/T: Service and Repair Selector Lever Transmission Selector Lever Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. Page 4965 Page 2921 GEN II ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. Page 7531 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. P1780 P1780 Page 3142 Page 3889 Symbols Part 5 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 electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 2 (25A) - 3 (25A) - 21 (40A) - Smart junction box (SJB) fuse(s): 1 (15A) (trailer parking lamps) - 6 (15A) - 17 (15A) - SJB - Circuity - Trailer 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. - Make sure the multifunction switch is in the low beam position. 5. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or ISO 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 Body Control Systems (Multifunction Electronic Control Module). - 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. See: Symptom Related Diagnostic Procedures NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are all functioning correctly with the trailer disconnected. Page 2358 14. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump. Remove the remaining bolts and position the power steering pump aside. 15. Disconnect the crankshaft position (CKP) sensor electrical connector. 16. NOTE: Whenever the CKP sensor is removed, a new one must be installed, using the alignment jig supplied with the new part. Remove and discard the CKP sensor. 17. Remove the bolts and the engine front cover. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the mounting surfaces of the engine and the front cover. Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 7776 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. Electrical Specifications Fuel Injector: Electrical Specifications Resistance ........................................................................................................................................... ............................................................. 11 - 18 Ohms Page 6702 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 6964 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 7700 92-2 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 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 7239 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 2854 Spark Plug: Service and Repair Spark Plug Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or wont or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture for excessive idling. ^ Install new spark plugs. Page 6493 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 6711 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 control arms. - provide a mounting point for the engine isolators. - provide the mounting surface for the steering gear. - provide the mounting surface for the sway bar. Page 4851 Page 1759 Spark Plug: Service and Repair Spark Plug Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or wont or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture for excessive idling. ^ Install new spark plugs. Page 7645 B2-B6 Normal Operation The horn relay is controlled by the horn switch. The horn relay is grounded through the horn switch by circuit 6 (YE/LG). When the horn switch is pressed, the horn relay control circuit 6 (YE/LG) is grounded through circuit 57 (BK). The relay is then closed causing B+ voltage to be applied to circuit 1 (DB), sounding the horns. The SJB can also supply a ground for the horn relay coil. Possible Causes - circuit 6 (YE/LG) shorted to ground - circuit 1 (DB) shorted to power - clockspring - horn relay - horn switch - horn switch harness - SJB Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Front Diagrams Page 5945 Air Bag Control Module: Diagrams Page 6408 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 3014 G8-G9 Normal Operation The medium speed CAN has an unshielded twisted pair cable, circuits 1847 (WH/OG) and 1848 (PK/OG). The smart junction box (SJB) and the instrument cluster are the only modules on the medium speed CAN. Total network resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open in one of the medium speed CAN circuits, damage to the data link connector (DLC) C251, damage to one of the network module connectors, or damage to an in-line connector. Since both the SJB and the instrument cluster share network termination responsibilities, a problem in either of these modules can result in a medium speed CAN failure. Possible Causes - medium speed CAN circuits 1847 (WH/OG) and 1848 (PK/OG) shorted to ground or open - SJB power circuit 1052 (TN/BK) open - SJB ground circuit 570 (BK/WH) open - DLC C251 - SJB - instrument cluster - battery junction box (BJB) fuse 19 (40A) Test H: No High Speed Controller Area Network (CAN) Communication PINPOINT TEST H: NO HIGH SPEED CONTROLLER AREA NETWORK (CAN) COMMUNICATION H1-H2 Page 3032 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 2619 Locations View 151-13 (Behind Dash Panel) Page 5850 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and Installation 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the system. 2. Detach the retaining clips and partially remove the instrument panel center trim panel. 3. Remove the passenger air bag deactivation indicator. 1 Release the red disconnect deterrent tab. 2 Disconnect the connector. 3 Release the 2 tabs (one shown). 4 Remove the passenger air bag deactivation indicator. Page 474 P1128 Page 7549 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 2016 Page 4945 Page 6775 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 264 P0402 Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation FUEL CAP INDICATOR LAMP The fuel cap indicator lamp (FCIL) is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed properly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. NOTE: The FCIL on the Crown Victoria/Grand Marquis, Explorer Sport Trac, and Ranger is a dedicated output signal that is controlled by the PCM. Page 7454 Symptom Chart Page 51 P0113 Page 5813 - is mounted above the headliner. - attaches from the A-pillar frame to the C-pillar frame. - There are 2 different safety canopy modules, 1 for vehicles equipped with a moon roof and 1 for vehicles without a moon roof. The safety canopy modules are NOT interchangeable. If installing a new safety canopy module, the correct safety canopy module MUST be installed for the vehicle application. Locations View 151-13 (Behind Dash Panel) P0480 P0480 Page 750 P2006 Page 7743 View 151-25 (Liftgate) Page 5820 Air Bag: Service and Repair Safety Canopy Module SAFETY CANOPY MODULE Part 1 System Diagnosis P1910 Page 3265 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 1832 - Evacuate, leak test, and charge the refrigerant system. Evaporator Inlet Line EVAPORATOR INLET LINE Removal and Installation 1. Recover the refrigerant. 2. Loosen the nuts and disconnect the evaporator inlet line fittings. - Remove and discard the O-rings. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the evaporator inlet line. 4. NOTE: New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Charge and leak test the refrigerant system. Evaporator Inlet Line - Orifice Tube EVAPORATOR INLET LINE - ORIFICE TUBE Page 4546 Brake Caliper: Service and Repair Caliper Disassembly and Assembly, Front Brake Caliper Material Material 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. Disassembly and Assembly 1. Remove the disc brake caliper. 2. Secure the brake caliper in a vise. 3. Remove the bleeder screw cap. 4. Remove the bleeder screw. ^ To install, tighten to 16 Nm (12 ft. lbs.). Page 928 Page 7458 J3-J4 Normal Operation The stoplamp switch is supplied battery voltage through circuit 10 (LG/RD) from the smart junction box (SJB). When the brake pedal is applied, the stoplamp switch allows voltage to flow through circuit 511 (LG). Circuit 511 (LG) sends voltage to the high mounted stoplamp and SJB, which in turn provides voltage to the LH and RH rear lamps. Possible Causes - circuit 10 (LG/RD) open - circuit 511 (LG) open - stoplamp switch - SJB Test K: One Or More Stoplamps Are Inoperative PINPOINT TEST K: ONE OR MORE STOPLAMPS ARE INOPERATIVE K1-K2 Specifications Valve Clearance: Specifications NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. If any tappets do not measure within specifications, install new tappets in these locations. Page 5870 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 6069 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. - 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 reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 driver seat safety belt buckle pretensioner is shown, the passenger side is similar. 1. Depower the SRS. 2. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the affected seat from the vehicle. 3. Remove the inboard seat cushion side shield. 1 Remove the front and rear side shield screws (front shown). 2 Remove the inboard seat cushion side shield. 4. Disconnect the safety belt buckle pretensioner electrical connectors. 5. NOTE: Note the wire harness routing for installation. Detach the pin-type retainers and separate the safety belt buckle and pretensioner electrical connectors and wire harness from the seat. 6. Remove the bolt and the safety belt buckle pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 7. To install, reverse the removal procedure. 8. Repower the SRS. 9. Check the active restraint system for correct operation. Service and Repair High Pressure Sensor / Switch: Service and Repair HIGH PRESSURE CUTOFF SWITCH Removal and Installation 1. Disconnect the high pressure cut-off switch electrical connector. 2. Remove the high pressure cut-off switch. 3. NOTE: A new O-ring seal lubricated with clean mineral oil must be installed before installing a new switch. To install, reverse the removal procedure. Specifications Drive Pulley: Specifications Coolant pump pulley bolts ................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 5538 View 151-13 (Behind Dash Panel) Page 2790 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the RH lower A-pillar trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Camber and Caster Adjustment Alignment: Service and Repair Camber and Caster Adjustment Camber and Caster Adjustment Front Camber and Caster Adjustment 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the front strut upper mounting bracket nuts. 3. Push the front strut mounting bracket downward and turn it to the desired position to set the camber and caster. Both camber and caster for the front suspension are adjustable. 4. NOTE: Notice the position of the strut rod in each position Use the following table for LH side camber and or caster adjustment. Locations View 151-14 (Under Dash Panel, LH Side) Service and Repair Auxiliary Water Pump: Service and Repair AUXILIARY COOLANT FLOW PUMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on hoist. 2. Drain the engine coolant. 3. Remove the lower splash shield. 4. Release the 2 clamps and disconnect the 2 auxiliary coolant flow pump heater hoses. 5. Disconnect the auxiliary coolant flow pump electrical connector. 6. Remove the 2 bolts and the auxiliary coolant flow pump. - To install, tighten to 7 Nm (62 lb-in). 7. NOTE: Lubricate the coolant hoses with water if needed. To install, reverse the removal procedure. Fill the engine cooling system. Page 4212 Special Tool(s) Removal NOTE: LH is shown, RH is similar. 4WD vehicles 1. Remove the wheel knuckle. FWD vehicles 2. Remove and discard the wheel hub nut. 3. Remove the Anti-Lock Brake System (ABS) wheel speed sensor ring. All vehicles Page 604 P1437 Testing and Inspection Radiator: Testing and Inspection Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners can be present in the cleaning tank and they will damage aluminum radiators. NOTE: Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator. NOTE: Clean the radiator before leak testing to avoid contamination of the tank. 1. Leak test the radiator in clean water with 138 kPa (20 psi) air pressure. Interior - Headliner Sagging Near Rear Hatch Headliner: Customer Interest Interior - Headliner Sagging Near Rear Hatch TSB 05-8-3 05/02/05 HEADLINER SAGGING NEAR REAR HATCH FORD: 2004-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2004-2005 vehicles may exhibit the headliner sagging around the rear hatch perimeter edge. ACTION Adhere the headliner to the underside of the roof panel. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the perimeter seal near the sagging edge (Figure 1). 2. Without removing the headliner push pins, pull the headliner down far enough to scuff/sand the back side of the headliner and the underside of the roof panel. 3. Prepare the cartridge of Motorcraft Plastic Bonding Adhesive (TA-9), and apply the adhesive to the back side of the headliner (Figure 2). Door Handle Rear Door Exterior Handle: Service and Repair Door Handle EXTERIOR REAR DOOR HANDLE Removal and Installation Exterior Rear Door Handle 1. Remove the rear door trim panel. 2. Position the watershield aside. 3. Position the rear door glass top run aside. 1 Remove the 2 bolts. To install, tighten to 8 Nm (71 lb-in). 2 Position the rear door glass top run aside. 4. Loosen the 2 exterior door handle reinforcement screws until the exterior door handle reinforcement slides free. 5. Remove the exterior door handle cover. 1 Pull the exterior door handle. 2 The front of the cover must be released prior to removing the cover. Page 3105 Main Relay (Computer/Fuel System): Testing and Inspection Page 7249 Compass: Adjustments Compass Calibration COMPASS CALIBRATION 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. 5. The compass is now calibrated. Specifications Clutch Fluid: Specifications Clutch Fluid Type .................................................................................................... Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Page 6444 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 5052 Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the 8 cowl panel grille pin-type retainers. 4. Remove the 8 cowl panel grille caps and screws. 5. Remove the LH cowl panel grille. 6. Remove the RH cowl panel grille. 7. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Page 1986 Service and Repair Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Press the tabs simultaneously and remove the blower motor switch. 4. To install, reverse the removal procedure. Hood Latch Hood Latch: Service and Repair Hood Latch HOOD LATCH Removal 1. Remove the hood latch nut. 2. NOTE: Mark the hood latch position prior to removal of the hood latch bolts. Remove the 2 hood latch bolts. 3. Remove the hood latch. 1 Release the cable conduit. 2 Disconnect the cable. Installation 1. Connect the hood latch release cable and conduit to the hood latch. 1 Connect the cable. 2 Engage the cable conduit. 2. NOTE: When the hood latch is installed, the latch adjustment must be checked to make sure the latch is installed and aligned correctly. Position the hood latch with the alignment marks and install the 2 hood latch bolts. Tighten to 9 Nm (80 lb-in). Page 5720 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 gauge port valve and the R-134a refrigerant center or manifold gauge set. 5. Open all the valves and inject the fluorescent dye into the refrigerant system. 6. When the fluorescent dye injection is complete, close all the valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure gauge port valve and the R-134a A/C 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 an 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. New 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 manufacturer instructions on evacuation of non-condensable gasses from the hoses. - The refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F). 1. Verify that the valves on the injector loop kit are closed. 2. Fill the injector loop kit reservoir with 7 ml (0.24 oz) of fluorescent dye. 3. Install the injector loop kit between the high-pressure and low-pressure 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. Page 642 P1504 Page 7383 Dimmer Switch: Testing and Inspection Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6341 Disclaimer Page 546 P1272 Page 6414 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Page 5341 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Wheel Cylinder Material Removal and Installation 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. 1. Remove the brake shoes. 2. Disconnect the brake line fitting nut. ^ To install, tighten to 15 Nm (11 ft. lbs.). 3. Remove the 2 wheel cylinder bolts and remove the wheel cylinder. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. ^ Bleed the brake hydraulic system. Page 6725 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 1966 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 3993 2. Remove the intake tube and air cleaner cover. 3. Remove the air cleaner as an assembly. 4. Install the special tools. 5. Install the special tools. Page 1128 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 1137 Connector Views Radiator Cooling Fan Motor: Connector Views Page 1944 Refrigerant: Service and Repair Contaminated Refrigerant Handling CONTAMINATED REFRIGERANT HANDLING 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 repair facility in your area with the correct equipment to carry out this repair. 2. Determine and correct the cause of the customer's initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Page 7017 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 7199 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 Parking Aid Sensor, Outer Left Page 4738 Starter Relay: Testing and Inspection 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. 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 3929 Shifter A/T: Service and Repair Selector Lever Knob Selector Lever Knob Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Disconnect the overdrive cancel switch electrical connector. Locations View 151-19 (Center Console) Page 7593 LH Headlamp Assembly 1. Remove the battery. Both 2. Release the rear cover retainer and remove the rear cover. 3. Disconnect the electrical connector and remove the low beam or high beam bulb. 4. To install, reverse the removal procedure. Locations View 151-19 (Center Console) Service and Repair Expansion Block/Orifice Tube: Service and Repair EVAPORATOR CORE ORIFICE Special Tool(s) Special Tool(s) NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. - New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. Removal 1. Remove the condenser to evaporator line. 2. Disconnect the condenser to evaporator spring lock coupling. 3. Inspect the evaporator core orifice for damage before attempting to remove it from the evaporator core inlet line. Page 3578 View 151-8 (Engine, rear) Page 4205 Service and Repair Wiper Motor Linkage: Service and Repair WIPER MOUNTING ARM AND PIVOT SHAFT Removal and Installation 1. Remove the cowl panel grille. 2. Remove the 3 windshield wiper mounting arm and pivot shaft assembly bolts and the windshield wiper mounting arm and pivot shaft assembly. - To install, tighten to 12 Nm (9 lb-ft). 3. Disconnect the windshield wiper motor electrical connector. 4. To install, reverse the removal procedure. Page 1825 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Disconnect the high pressure cut-off switch electrical connector. 5. Remove the condenser to evaporator line bracket nut. - To install, tighten to 8 Nm (71 lb-in). 6. Disconnect the evaporator core spring lock coupling. 7. Remove the condenser to evaporator line peanut fitting nut and disconnect the line. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the condenser to evaporator line. 9. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. P2015 P2015 Page 7668 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 3896 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 6914 Page 1099 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 251 P0356 Diagrams Page 547 P1273 Locations View 151-7 (Engine, front) Locations Specifications Timing Chain Guide: Specifications Timing chain guide bolts ...................................................................................................................... ................................................. 10 Nm (89 inch lbs.) Page 7525 G2 Normal Operation The battery saver provides voltage to circuit 1005 (VT/OG). Circuit 1005 (VT/OG) provides voltage to each demand lamp. Each demand lamp switch, when activated, provides ground to the selected lamp. The lamps are grounded through circuit 570 (BK/WH) or 57 (BK). The battery saver deactivates the voltage circuit when the SJB has timed out. Possible Causes - circuit 1005 short to voltage - SJB Initial Inspection and Diagnostic Overview Horn: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The horn relay B+ power and the horn relay switched power are supplied through circuit 1682 (RD/LB). The horn relay is controlled by the horn switch. The horn relay is grounded through the horn switch by circuit 6 (YE/LG). When the horn switch is pressed, the horn relay control circuit 6 (YE/LG) is grounded. The relay is then closed causing B+ voltage to be applied to circuit 1 (DB), sounding the horns. The horn relay is powered on both the control and controlled sides by circuit 1682 (RD/LB). When the horn switch is pressed, the horn relay control circuit 6 (YE/LG) is grounded through the horn switch. The horn relay is then energized, allowing battery voltage to flow through the horn relay to each horn through circuit 1 (DB), enabling the horns to sound. When the vehicle security system is armed, the smart junction box (SJB) provides a momentary ground to the horn relay control side to indicate the system is armed, and a continuous ground when an intrusion is detected. Inspection and Verification 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, connect the diagnostic tool to the data link connector (DLC) 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 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: - CAN or ISO circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for the SJB, go to Body Control Systems (Multifunction Electronic Control Module). - 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 no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnosis. See: Symptom Related Diagnostic Procedures Locations View 151-3 (Engine Compartment, 1 Of 2) P2100 P2100 Page 5748 View 151-13 (Behind Dash Panel) Diagrams Page 3847 Seals and Gaskets: Service and Repair Differential Seals - RH Differential Seals-RH Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. Page 296 P0454 Page 2458 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 1195 Page 7548 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 8008 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 6826 C. Drill the hole at a slow to moderate pace, occasionally pulling the bit out to clear the chips. D. Drill the hole to the proper depth using the stop on the bit as your depth gauge. See Figure 6. E. Drill the second hole in the same foam block in the same manner. F. Repeat steps A - E on the foam block on the other side of the headliner. 5. Remove the covers from the instrument panel and clean all foam chips from the vehicle. Proceed to ASSEMBLY. ASSEMBLY 1. Position the B-pillar trim panels and install the bolts. Tighten to 7 Nm (62 lb-in), then install the bolt covers. 2. Position the safety belt and install the safety belt bolts at the B-pillar. Tighten to 53 Nm (39 lb-ft), then install the D-ring covers. 3. Install the A-pillar trim panels. 4. Install the passenger A-pillar assist handles and bolts. Tighten to 5 Nm (44 lb-in), then install the bolt covers. 5. Install the front and rear door weatherstrips. 6. Connect and install the overhead console, if equipped. 7. Install and connect the interior lamp and screws. 8. Install the interior lamp lens. 9. Install the sunvisors, connecting the electrical connectors if equipped, and the sunvisor clips. 10. Install the rear seat overhead assist handles and bolts. Tighten to 8 Nm (71 lb-in), then install the bolt covers. Owner Letter Owner Notification Letter will be mailed on May 19, 2006. Page 995 Main Relay (Computer/Fuel System): Testing and Inspection Page 5317 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Transmission Range (TR) Sensor Page 2797 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts SAFETY BELT SHOULDER HEIGHT ADJUSTER WITH STRIPPED WELD NUTS D-Ring Installation Kit Special Tool(s) 1. Remove the trim panels. 2. Use the half-inch drill provided in D-Ring Installation Kit 100-F012 (134-00018) or equivalent to drill out the damaged threads in the upper B-pillar structure. 3. NOTE: After each rotation, back tap off slightly to remove new cuttings and be sure to clean out any chips before proceeding. Apply a suitable lubricant to the M14 x 1.5 tap provided in D-Ring Installation Kit 100-F012 (134-00018) and tap new threads. Specifications Pressure Plate: Specifications Clutch pressure plate bolts Tighten ................................................................................................................................................. ............................. 29 Nm (21 ft.lbs.) in sequence. Service and Repair Headlamp Bulb: Service and Repair HEADLAMP BULB Removal and Installation WARNING: The halogen headlamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. CAUTION: The headlamp bulb should not be removed from the headlamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. Locations View 151-7 (Engine, front) Page 5810 Air Bag: Diagrams Side Air Bag Module Page 6510 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 5234 Figure 2 - Shows a new bushing prior to assembly into the control arm. Bolt number 2 passes through the inner sleeve and the outer sleeve is pressed into the control arm. The rubber bushing is bonded to both the inner and outer sleeves. Figure 3 - Illustrates a generic bushing showing minor sur[ace cracks that do not adversely affect the performance of the bushing. Bushings exhibiting sur[ace cracks with a depth less than 3/8" (10 mm) are acceptable and will continue to function normally. These do not require replacement. Figure 4 - Illustrates a partial separation between the rubber and the outer sleeve. The bushing may show signs of movement on the rubber surface, making the surface shiny. Bushings with a separation or crack depth less than or equal to 3/8" (10 mm) are acceptable and meet all functional requirements. These do not require replacement. Bushings with a separation or crack greater than 3/8" (10 mm) in depth should be replaced. The customer may hear a bang or clunk in the front suspension if there is enough separation for the arm to contact the subframe. This does not affect the retention of the control arm to the vehicle as the bushing is sandwiched in the subframe and held in place with the bolt. The vehicle can be safely operated in this condition until the bushing is replaced. Front Door Handles, Locks and Latches - Exploded View Front Door Latch: Service and Repair Front Door Handles, Locks and Latches - Exploded View FRONT DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 4822 Page 5438 Disclaimer Page 4470 Page 3640 Camshaft Position Sensor: Diagrams Page 5881 1. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the B-pillar sheet metal. 2. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 3. Connect the side impact sensor electrical connector. 4. Install the B-pillar trim panel. 5. Repower the system. A/C - Instrument Panel Vents Hard to Adjust Air Register: Customer Interest A/C - Instrument Panel Vents Hard to Adjust TSB 04-25-13 12/27/04 SERVICEABILITY OF INSTRUMENT PANEL REGISTER VENTS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 vehicles may exhibit instrument panel (IP) register vents that are difficult to adjust or are limited in their adjustability. ACTION Register vents for the IP center finish panel can now be ordered and replaced individually. Replacement of an entire center finish panel assembly to correct a register vent condition is no longer necessary. The IP outboard register vents can be replaced similarly without replacing the entire housing assembly, however, the outboard vent must be ordered as an assembly with the housing. Refer to the following Service Procedure. SERVICE PROCEDURE CENTER REGISTER REPLACEMENT 1. Remove center finish panel. Refer to Workshop Manual Section 501-12. 2. With center finish panel removed, release the register retention tabs and remove the register. 3. Replace register with Part Number YL8Z-19893-CAA left or YL8Z-19893-CAB right. 4. Reinstall the center finish panel. OUTBOARD REGISTER REPLACEMENT 1. Tilt the vehicle's outboard register to the down most position. Pull the top of the register out until it is released from the housing. 2. Remove the new register from the service replacement register housing assembly (base # -19893-), as described in Step 1. 3. Snap the new register into the vehicle's existing outboard register housing. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042513A Register Replace Right 0.2 Hr. Outboard Vent Only 042513B Register Replace Left 0.2 Hr. Outboard Vent Only 042513C Register Replace Both 0.4 Hr. Center Vents (Includes Time To Remove And Left Front Page 7141 2 Connect the electrical connector. 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. Page 38 P0103 Page 6062 Page 1934 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 gauge port valve and the R-134a refrigerant center or manifold gauge set. 5. Open all the valves and inject the fluorescent dye into the refrigerant system. 6. When the fluorescent dye injection is complete, close all the valves. 7. Recover the refrigerant from the R-134a fluorescent dye injector. 8. Remove the fluorescent dye injector from the low-pressure gauge port valve and the R-134a A/C 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 an 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. New 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 manufacturer instructions on evacuation of non-condensable gasses from the hoses. - The refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F). 1. Verify that the valves on the injector loop kit are closed. 2. Fill the injector loop kit reservoir with 7 ml (0.24 oz) of fluorescent dye. 3. Install the injector loop kit between the high-pressure and low-pressure 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. Page 5542 Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: 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 4 to 8 seconds with no chime. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver's 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 Seat Belt Systems. Page 1972 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Connector Views Alternator: Connector Views Page 6102 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the B-pillar trim panel. 3. Disconnect the side impact sensor electrical connector. 4. Remove the bolt and the side impact sensor. Installation Fuel Tank Pressure Transducer Sensor View 151-15 (Full Body, Left Rear - 1 Of 2) Page 5666 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. Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand 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 IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Adjustments Shift Linkage: Adjustments Gearshift Cable Adjustment 1. Set the parking brake. 2. Remove the floor console. 3. Disengage the secondary shift cable lock by sliding it away from the shifter ball stud. 4. NOTE: If the primary shift cable lock is difficult to slide out, disconnect the shift cable from the ball stud, push the primary lock from the rear, and reattach the shift cable to the ball stud. Disengage the primary shift cable lock by sliding it out away from the shift cable. 5. With the shifter and the transmission in NEUTRAL, engage the primary shift cable lock. Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 265 P0403 Page 6120 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Page 7136 Page 1533 Page 3377 Symptom Chart Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Page 1225 Oil Pressure Sender: Service and Repair Oil Pressure Sender Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Disconnect the oil pressure sender electrical connector. 4. Remove the oil pressure sender. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. To install, reverse the removal procedure. ^ Apply pipe sealant with Teflon to the oil pressure sender threads. System Diagnosis P1184 Page 1414 Power Steering Pressure Switch: Diagrams Page 2710 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the HO2S. To install, tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensor. To install, reverse the removal procedure. Page 561 P1289 Page 5379 Remove the upper stabilizer bar link nut. 6. Remove the 2 strut-to-knuckle nuts and bolts. 7. NOTE: Reference mark the 4 strut upper bushing plate nuts. Remove the 4 strut upper bushing nuts. 8. CAUTION: Do not allow the axle shaft to move outboard. Over-extension of the tripod CV joint can result in the separation of internal parts, causing failure of the axle shaft. Remove the strut and spring assembly. Installation 1. Position the strut and spring assembly upper mounting plate into the inner fender. 2. Align the 4 strut upper bushing nuts to the reference marks. ^ Tighten to 40 Nm (30 ft. lbs.). 3. Install the 2 strut-to-knuckle bolts and nuts. ^ Tighten to 115 Nm (85 ft. lbs.). 4. Install the upper stabilizer bar link nut. ^ Tighten to 63 Nm (46 ft. lbs.). 5. Install the ABS wheel speed sensor harness bolt. ^ Tighten to 23 Nm (17 ft. lbs.). 6. Position the brake jounce hose to the bracket and install the brake jounce hose clip. 7. Check the front end alignment and adjust as necessary. Disassembly and Assembly Strut and Spring Assembly Disassembly and Assembly Page 7499 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 4621 Brake Caliper: Service and Repair Caliper Disassembly and Assembly, Front Brake Caliper Material Material 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. Disassembly and Assembly 1. Remove the disc brake caliper. 2. Secure the brake caliper in a vise. 3. Remove the bleeder screw cap. 4. Remove the bleeder screw. ^ To install, tighten to 16 Nm (12 ft. lbs.). Page 5822 6. Disconnect the safety canopy module electrical connector and detach the connector from the D-pillar. 7. Detach the safety canopy module wiring clip from the roof panel brace. 8. Remove the 2 safety canopy module bolts near the ignitor (between the C and D-pillars). 9. If the vehicle is equipped with a moonroof, disconnect the moonroof rear drain hose. 10. If the vehicle is equipped with a rear window wiper assembly, detach the hose clips and position the hose aside. 11. Remove the 2 bolts from the safety canopy module tether at the B-pillar. 12. Remove the remaining 2 safety canopy module bolts (1 near the top of the C-pillar, 1 between the B and C-pillars). Page 7631 Horn: Connector Views Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 3088 GEN II ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. Locations View 151-19 (Center Console) Page 6317 F1-F3 Normal Operation The audio unit receives input signals through the medium speed CAN and the audio control protocol (ACP) module. The navigation system then computes and displays the high energy power flow and miles per gallon data when selected. Possible Causes - circuit 1847 (WH/OG) open - circuit 1848 (PK/OG) open - instrument cluster Test G: The Navigation System Does Not Operate Correctly - The Fuel Economy and Energy Flow Screens Cannot Be Selected or Do No PINPOINT TEST G: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - THE FUEL ECONOMY AND ENERGY FLOW SCREENS CANNOT BE SELECTED OR DO NOT REMAIN SELECTED Page 3562 Exploded View Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH inner fender splash shield. 3. Remove the bolt and the air intake resonator. - To install, tighten to 8 Nm (71 lb-in). 4. NOTE: Make sure that the front rubber grommet is seated in the bracket. To install, reverse the removal procedure. Page 3882 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 104 P0156 Page 4704 Disclaimer Locations Page 5792 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 1581 a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connector(s) and wiring clips. 1 Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2 Release the 2 wiring clips on the wiring harness from the cushion pan. 3 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Page 4422 4. Install a new dust shield. 5. Install the transfer case vent tube. ^ Install the 2 transfer case vent tube bolts. ^ Tighten to 30 Nm (22 ft. lbs.). 6. Install the transfer case. Service and Repair Rear Bumper Cover / Fascia: Service and Repair REAR BUMPER COVER Escape Is Shown, Mariner Is Similar (Part 1) Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity ...................................................................................................................... ........................................................... 266 ml. (9 oz.) Page 5082 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Page 6261 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 6147 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 6. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). 7. Connect the electrical connector(s) and wiring clips. 1 Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2 Install the 2 wiring clips on the wiring harness to the cushion pan. 3 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 4 Tie strap the unused seat wire harness pressure sensor electrical connector safely out of the way. 5 Tie strap all loose wire harnesses and electrical connectors safely out of the way. 8. Install the passenger seat into the vehicle. 9. Repower the system. Do not prove out the system at this time. 10. CAUTION: - 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. Page 1329 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Locations View 151-8 (Engine, rear) A/C - Instrument Panel Vents Hard to Adjust Air Register: All Technical Service Bulletins A/C - Instrument Panel Vents Hard to Adjust TSB 04-25-13 12/27/04 SERVICEABILITY OF INSTRUMENT PANEL REGISTER VENTS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 vehicles may exhibit instrument panel (IP) register vents that are difficult to adjust or are limited in their adjustability. ACTION Register vents for the IP center finish panel can now be ordered and replaced individually. Replacement of an entire center finish panel assembly to correct a register vent condition is no longer necessary. The IP outboard register vents can be replaced similarly without replacing the entire housing assembly, however, the outboard vent must be ordered as an assembly with the housing. Refer to the following Service Procedure. SERVICE PROCEDURE CENTER REGISTER REPLACEMENT 1. Remove center finish panel. Refer to Workshop Manual Section 501-12. 2. With center finish panel removed, release the register retention tabs and remove the register. 3. Replace register with Part Number YL8Z-19893-CAA left or YL8Z-19893-CAB right. 4. Reinstall the center finish panel. OUTBOARD REGISTER REPLACEMENT 1. Tilt the vehicle's outboard register to the down most position. Pull the top of the register out until it is released from the housing. 2. Remove the new register from the service replacement register housing assembly (base # -19893-), as described in Step 1. 3. Snap the new register into the vehicle's existing outboard register housing. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042513A Register Replace Right 0.2 Hr. Outboard Vent Only 042513B Register Replace Left 0.2 Hr. Outboard Vent Only 042513C Register Replace Both 0.4 Hr. Center Vents (Includes Time To Remove And Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 6927 Power Mirror Switch: Testing and Inspection Service and Repair Global Positioning System Module: Service and Repair AUDIO CONTROL PROTOCOL (ACP) MODULE Removal and Installation 1. Disconnect the battery. 2. Lower the glove box. 3. Remove the 2 ACP module screws. 4. Disconnect the electrical connectors and remove the ACP module. 5. To install, reverse the removal procedure. Page 5404 Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Strut and Spring Assembly Removal NOTE: LH side is shown, RH side is similar. 1. NOTE: Verify the steering wheel is in the unlocked position before removal. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake jounce hose clip. 3. Pull the brake jounce hose downward slightly to remove the hose from the bracket and position the brake jounce hose aside. 4. Remove the ABS wheel speed sensor harness bolt. 5. NOTE: Use the hex holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Remove the upper stabilizer bar link nut. 6. Remove the 2 strut-to-knuckle nuts and bolts. Page 2776 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 5690 Heater Hose To Oil Cooler Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. If removing the heater core hoses, remove the heater hose tie. 4. Release the clamps and remove the necessary heater hose(s). 5. To install, reverse the removal procedure. NOTE: Lubricate the coolant hoses with plain water only if needed. Fill the engine cooling system. Page 1677 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: - The LH front window control switch is shown, all others are similar. - The removal and installation procedures for all window control switches are similar. 1. Remove the front door trim panel or the rear door trim panel. 2. Release the window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Page 1487 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Locations View 151-7 (Engine, front) P1380 P1380 Page 4122 3. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 4. Adjust the shift cable. Page 5062 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. Service and Repair Rear Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Removal NOTE: LH is shown, RH is similar. Drum brake vehicles 1. Remove the brake shoes. 2. Disconnect the parking brake cable from the brake backing plate. ^ Remove the parking brake cable from the brake backing plate. 3. Disconnect the brake line from the wheel cylinder and remove the brake line bracket bolt. Disc brake vehicles 4. Remove the parking brake shoes. 5. Remove and discard the wheel hub nut. Page 6473 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 4260 1. Using the special tool, install the halfshaft oil seal. 2. CAUTION: Make sure to use the seal protector when installing the RH intermediate shaft and the LH halfshaft. Failure to use the seal protector may result in transmission oil leaks. Install the RH intermediate shaft or LH halfshaft. Page 1056 Heated Glass Element Relay: Testing and Inspection Page 5188 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 4605 Wheel Cylinder: Service and Repair Disassembly and Assembly Wheel Cylinder Material Disassembly and Assembly 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. 1. Remove the rear wheel cylinder. 2. Remove the bleeder screw cap. 3. Remove the bleeder screw. ^ To install, tighten to 8 Nm (71 inch lbs.). 4. Remove the 2 dust boots. 5. Remove the 2 pistons. 6. Remove the 2 piston seals. ^ To install, lubricate the piston seals with clean brake fluid. 7. Remove the spring. 8. NOTE: Inspect the wheel cylinder bore for excessive wear, corrosion, or pitting. If any of these conditions exist, a new wheel cylinder must be installed. P0705 P0705 Page 7722 Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Page 4987 Page 5824 2. NOTE: If equipped with a moonroof and/or rear window wiper assembly, make sure of correct moonroof drain hose and/or rear window solvent hose routing. Install the safety canopy rear hook. 3. Hook the safety canopy module to the C-pillar. 4. Install the 2 safety canopy module bolts located near the top of the A and B-pillars. - Tighten to 8 Nm (71 lb-in). 5. If installing the same safety canopy module, join the tether to the pin-type retainer. If a new safety canopy module is being installed, attach the tether with the pin-type retainer. 6. NOTE: If equipped with a moonroof and/or rear window wiper assembly, do not pinch the front moonroof drain hose and/or rear window washer solvent hose. Install the A-pillar tether bolt. Tighten to 8 Nm (71 lb-in). 7. Install the 2 safety canopy module bolts near the top of the C-pillar and between the B and C-pillars. - Tighten to 8 Nm (71 lb-in). 8. Install the 2 bolts to the safety canopy module tether at the B-pillar. - Tighten to 8 Nm (71 lb-in). 9. If the vehicle is equipped with a rear window wiper assembly, position the hose and attach the hose clips. Page 7258 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 1160 Page 5845 5. NOTE: The RCM has been removed for clarity. Connect the large RCM electrical wiring 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. 6. Position back the carpet on the LH and RH tunnel to its original position. 7. Install the lower LH center instrument panel finish panel. 8. Repower the system. Tires - Vibration Highway at Speeds Tires: All Technical Service Bulletins Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 3543 Page 7680 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 942 Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 7428 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 1942 1. Connect an R-134a refrigerant center to the low pressure and high pressure 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 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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 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 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 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 Refrigerant Center NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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 center to the low-side and high-side 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: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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. Locations View 151-7 (Engine, front) Locations View 151-8 (Engine, rear) Connector Views Fuse Block: Connector Views Page 4843 Page 7204 Symbols Part 4 Page 2716 Power Steering Pressure Switch: Diagrams Page 4814 Fuse Block: Locations Battery Junction Box Page 498 P1158 Deactivator Switch Page 7430 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 151-7 (Engine, front) Page 2547 Catalytic Converter: Service and Repair Catalytic Converter Catalytic Converter Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 exhaust catalytic converter nuts. ^ To install tighten to 47 Nm (35 ft. lbs.). 3. Remove and discard the U-bolt clamp assembly from the muffler. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Remove and discard the 2 resonator nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 5. Remove and discard the catalytic converter exhaust hanger. 6. Remove the exhaust catalytic converter and the muffler from the vehicle as an assembly. 7. Separate the converter from the muffler. 8. To install, reverse the removal procedure. ^ Install new gaskets. Page 3826 Fluid - A/T: Service and Repair Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Flush with clean transmission fluid only. Do not use solvents, mineral spirits or water-based cleaners. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Backflush any contaminates out of the oil-to-air cooler by connecting the flushing machine pressure line to number 1 and the return line to number 2. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. 2. Backflush any contaminants out of the radiator in-tank cooler by connecting the flushing machine pressure line to number 2 and the return line to number 3. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. Transmission Range (TR) Sensor View 151-10 (Automatic Transmission) Page 2733 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Page 3721 Spark Plug: Service and Repair Spark Plug Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or wont or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture for excessive idling. ^ Install new spark plugs. Service and Repair Fuel Supply Line: Service and Repair FUEL LINES Page 5362 Rear Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 4524 6. Remove the front wheel speed sensor bolt from the wheel knuckle. ^ To install, tighten to 9 Nm (80 inch lbs.). 7. NOTE: Clean off any debris that may have collected around the sensor before removal. Remove the front wheel speed sensor. 8. NOTE: Thoroughly clean the mounting surface. To install, reverse the removal procedure. Page 3236 Page 7532 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 5879 6. NOTE: Align the hood latch position as previously marked during removal. Install the hood latch assembly. 1 Position the hood latch. 2 Install the hood latch bolts. Tighten to 9 Nm (80 lb-in). 3 Tighten the hood latch nut. Tighten to 9 Nm (80 lb-in). 7. CAUTION: Make sure the hood latch is fully engaged. Verify the hood latch striker is fully engaging the hood latch. 8. Repower the system. Page 6308 Audio Control Protocol (ACP) Module C2294b Audio Unit C229a Audio Unit C229c Page 6890 Keyless Entry Key-Pad: Service and Repair REMOTE KEYLESS ENTRY KEYPAD Removal and Installation 1. Remove the LH front door trim panel. 2. Position the watershield aside. 3. Remove the RKE keypad retaining clip. 4. Remove the RKE keypad from the door. - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Page 5701 Hose/Line HVAC: Service and Repair Suction Accumulator to Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Page 821 P2196 Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The MIL notifies the driver that the powertrain control module (PCM) has detected an OBD emission-related component or system fault. When this occurs an OBD diagnostic trouble code (DTC) will be set. ^ The MW is located in the instrument cluster and is labeled CHECK ENGINE SERVICE ENGINE SOON or the ISO standard engine symbol. ^ The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. ^ For applications with a dedicated hard wire MIL circuit the PCM will illuminate the MIL until a profile ignition pickup (PIP) signal is detected. For 2OO5 the following vehicles use a hard wire circuit: Crown Victoria/Grand Marquis Explorer Sport Trac and Ranger. ^ The MIL will remain illuminated after instrument cluster prove out if: ^ an emission related concern and DTC exists. ^ no PIP signal is detected (applications with a dedicated hard-wire MIL circuit). The PIP signal is generated in the PCM using the crankshafi position (CKP) sensor. For these applications the MIL can be helpful in diagnosing a no start. ^ the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). ^ the PCM is operating in the Hardware Limited Operation Strategy (KLOS). ^ the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit). ^ The MIL remains off during the instrument cluster prove out if: ^ an indicator or instrument cluster concern is present. ^ the MIL circuit is open (applications with a dedicated hard wire MIL circuit). ^ To turn off the MIL afier a repair a reset command from the diagnostic tool must be sent or 3 consecutive drive cycles must be completed without a fault. ^ For all MIL concerns go to Symptom Charts. ^ If the MIL flashes at a steady rate a severe misfire condition may exist. ^ If the MIL flashes erratically the PCM can reset while cranking if the battery voltage is low. Page 6072 9. Deploy the safety belt pretensioner by touching the other ends of the 2 wires to the terminals of a 12-volt battery. 10. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt pretensioner. 11. Dispose of the deployed safety belt pretensioner in the same manner as any other part to be scrapped. Page 2402 Spark Plug: Service and Repair Spark Plug Inspection Spark Plug Inspection 1. Inspect the spark plug for a bridged gap. ^ Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. ^ Clean the spark plug. 2. Check for oil fouling. ^ Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or wont or loose bearings. ^ Correct the oil leak concern. ^ Install a new spark plug. 3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture for excessive idling. ^ Install new spark plugs. Locations P0552 P0552 Page 6560 5. Remove and discard the 3 door latch bolts. - To install, tighten to 8 Nm (71 lb-in) 6. Disconnect the door latch electrical connector. 7. Remove the door latch assembly. - Slide the door latch towards the front of the vehicle. 8. To install, reverse the removal procedure. - Lubricate the door latch to striker surfaces after installation. Page 4844 Page 1010 Locations View 151-7 (Engine, front) Page 5533 Blower Motor: Service and Repair BLOWER MOTOR Removal and Installation 1. Remove the RH A-pillar lower trim panel. 2. Disconnect the blower motor electrical connector. 3. Remove the 3 blower motor screws and the blower motor. 4. To install, reverse the removal procedure. Page 2557 Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. Windshield Wiper Blade and Pivot Arm Adjustment Wiper Blade: Adjustments Windshield Wiper Blade and Pivot Arm Adjustment WINDSHIELD WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the windshield wipers 2. Verify that the RH and LH wiper blades are located at the specified position. 3. If not within specification, remove the nuts and the windshield wiper pivot arms and reposition them to the correct locations. - To install, tighten to 35 Nm (26 lb-ft). Locations View 151-19 (Center Console) Page 5210 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 4774 Front Suspension Strut / Shock Absorber: Service and Repair Front Strut and Spring Assembly Disassembly and Assembly 1. WARNING: Always wear safety goggles when using a spring compressor. Failure to follow these instructions may result in personal injury. NOTE: Do not use an impact wrench on the nut. Mount the strut and spring assembly in a suitable spring compressor. 2. Compress the coil spring enough to relieve the tension on the strut assembly. 3. Remove the strut piston rod-to-bushing nut. ^ To assemble, tighten to 103 Nm (76 ft. lbs.). 4. Remove the strut. 5. Remove the lower coil spring insulator. 6. Remove the coil spring. 7. Remove the upper coil spring insulator. 8. NOTE: During assembly, assemble the bearing plate to the strut so the arrow on the bearing plate points to the outboard side of the vehicle when Service and Repair Blower Motor Switch: Service and Repair BLOWER MOTOR SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the blower motor switch knob. 3. Press the tabs simultaneously and remove the blower motor switch. 4. To install, reverse the removal procedure. Page 844 Accessory Delay Relay: Testing and Inspection Page 5783 Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After A Collision SAFETY BELT PROCEDURE AFTER A COLLISION 1. 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 replaced unless a qualified technician finds the assemblies show no damage and operate correctly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress. Before installing the 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 reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test. Page 1645 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 2128 Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced. - Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Cam Timing (VCT) System Variable Cam Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system 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 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Locations Page 1878 Fluid - A/T: Fluid Type Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Page 7203 Symbols Part 3 Page 1410 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. To install, reverse the removal procedure. System Diagnosis P0310 - P0314: Testing and Inspection P0310 (Part 1) P0310 (Part 2) P030x P030x Page 1361 Fuel Level Sensor: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 3860 Page 5898 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Page 6310 A1-A2 Page 3007 F1 Page 2631 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 6866 Headliner: Service and Repair HEADLINER Part 1 Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 5917 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. CAUTION: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and detach OCS ECU from the seat cushion pan. 9. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, ECU and connectors) through the seat cushion pan opening. Installation 1. Bend the retaining tab back on the pressure sensor component bracket. Page 3424 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Engine Cooling Fan Motor 1 View 151-3 (Engine Compartment, 1 Of 2) Page 4912 Page 5501 2. Remove the 2 vacuum control motor screws. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 3. To install, reverse the removal procedure. Page 2991 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. Windshield Wiper Motor Wiper Motor: Service and Repair Windshield Wiper Motor WINDSHIELD WIPER MOTOR Removal and Installation 1. Remove the windshield wiper mounting arm and pivot shaft. 2. Remove the wiper motor linkage bolt. - To install, tighten to 17 Nm (13 lb-ft). 3. Remove the 3 bolts and the wiper motor. - To install, tighten to 15 Nm (11 lb-ft). 4. To install, reverse the removal procedure. Specifications Piston: Specifications Piston Diameter (1) ......................................................................................................................................... .......................... 87.5-87.51 mm (3.444-3.445 in.) Diameter (2) ............................................................................................................................................................. 87.51-87.52 mm (3.4452-3.4456 in.) Diameter (3) .............................................................................. ................................................................................... 87.52-87.53 min (3.444-3.446 in.) Piston-to-bore clearance .......................................................................................................................................... 0.025-0.045 min (0.0009-0.0017 in.) Ring groove width - top ........................................................................................................................................... 1.203-1.205 min (0.0473-0.0474 in.) Ring groove width - 2nd .............................................................................................................................................. 1.17-1.19 min (0.0460-0.0468 in.) Ring groove width - oil ............................................................................................................................................ 2.501-2.503 min (0.0984-0.0985 in.) Piston skirt coating thickness ................................................................................................................................... 0.008-0.020 min (0.0003-0.0007 in.) Piston Pin Diameter .............................................................................................................................................. .................... 20.995-21.0 min (0.8266-0.8268 in.) Length .................................................................. ............................................................................................................ 59.6-60.4 min (2.346-2.377 in.) Piston-to-pin clearance ............................................................................................................................................ 0.008-0.016 min (0.0003-0.0006 in.) Pin-to-rod clearance .................................................................. ............................................................................................................................ Press fit System Diagnosis P0510 - P0514: Testing and Inspection P0511 (Part 1) P0511 (Part 2) Catalytic Converter - Manifold Catalytic Converter: Service and Repair Catalytic Converter - Manifold Catalytic Converter-2.3L Manifold Special Tool(s) Material Page 492 P1152 Service and Repair Vacuum/Pressure Pump: Service and Repair LUMBAR ASSEMBLY Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the SRS depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat backrest cover and depower the SRS. 2. Remove the front seat backrest cushion. 3. Remove the 2 manual lumbar control screws and the manual lumbar assembly. - To install, tighten to 3 Nm (27 lb-in). 4. To install, reverse the removal procedure. System Diagnosis P0445 - P0449: Testing and Inspection P0446 (Part 1) P0446 (Part 2) Page 7191 4. To install, reverse the removal procedure. 5. Repower the system. Page 1083 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 2020 Page 909 Locations View 151-20 (Driver Seat) Page 4848 Page 1051 Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Page 3340 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 4679 Vacuum Brake Booster: Service and Repair Brake Booster Removal and Installation 1. Disconnect the battery. 2. NOTE: Install new master cylinder nuts. Remove and discard the 2 master cylinder nuts. ^ To install, tighten to 25 Nm (18 ft. lbs.). 3. NOTE: It is not necessary to disconnect the brake tube fittings. Carefully position the brake master cylinder assembly forward. 4. Disconnect the vacuum hose/check valve assembly from the brake booster. 5. Remove the brake pedal position (BPP) switch. 6. If equipped, remove the speed control deactivator switch. Page 244 P0352 Page 2997 PC1 Anti-Lock Brake System (ABS) Module C155 Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 2774 Page 6011 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 4182 Axle Shaft Assembly: Description and Operation Rear Drive Halfshafts Rear Drive Halfshafts CAUTION: An inspection of the outer and inner boots is necessary so that if damage or grease leakage is evident, installation of a new halfshaft can take place immediately. Continued operation with damage or grease leakage will result in CV joint wear and noise due to contamination and loss of the CV joint grease. NOTE: Handle all halfshaft components carefully during removal and installation procedures. ^ The inner and outer Constant Velocity (CV) joints connect to a splined shaft. A circlip stopper holds the cross groove inner race assembly (inner CV joint) together. ^ The RH and LH halfshafts are the same length. ^ An axle circlip retains the splined inner CV joint to the differential side gear. Install a new axle circlip each time the halfshaft is removed from the vehicle. ^ A rear axle wheel hub nut secures the side shaft assembly (interconnecting shaft and outer CV joint) to the rear hub. Install a new rear axle wheel hub nut each time the halfshaft is removed from the vehicle. Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 7180 Page 2154 Lifter / Lash Adjuster: Service and Repair Valve Tappets Valve Tappets Material Removal and Installation 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the camshafts. 3. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. Remove and inspect the valve tappets. 4. To install, reverse the removal procedure. ^ Coat the valve tappets with clean engine oil prior to installation. Page 2987 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Output Shaft Speed (OSS) Sensor Page 4515 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 4421 5. Remove the transfer case driven gear seal. 6. CAUTION: The transfer case cover and case sealing surfaces must be free of grease prior to applying new silicone sealant. Clean the transfer case sealing surfaces. Installation 1. Using the special tool, install the transfer case driven gear seal. 2. CAUTION: Take care not to roll the transfer case inner halfshaft seal lip when installing the drive gear. Install the gears. 1 Install the drive gear. ^ Install the drive gear using a slight rotation to prevent damaging the transfer case inner halfshaft seal. 2 Install the idler gear. 3 Install the driven gear. 3. CAUTION: The transfer case cover must be installed within 15 minutes of applying the silicone sealant. If the time limit is exceeded, clean the sealing surfaces and reapply. NOTE: Apply a 3 mm (0.11 inch) bead of silicone gasket and sealant to the sealing surface of the transfer case cover before installing it on the transfer case. Install the transfer case cover. ^ Install the 12 transfer case cover bolts in a cross pattern. ^ Tighten to 32 Nm (24 ft. lbs.). Page 5275 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Description and Operation Fuel Filler Cap Warning Indicator: Description and Operation FUEL CAP INDICATOR LAMP The fuel cap indicator lamp (FCIL) is a communications network message sent by the PCM. The PCM sends the message to illuminate the lamp when the strategy determines that there is a failure in the vapor management system due to the fuel filler cap not being sealed properly. This would be detected by the inability to pull vacuum in the fuel tank, after a fueling event. NOTE: The FCIL on the Crown Victoria/Grand Marquis, Explorer Sport Trac, and Ranger is a dedicated output signal that is controlled by the PCM. Locations View 151-7 (Engine, front) Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ........................................................... 4.25L (4.5 Qt) Page 2788 Page 5020 Relay Box: Locations Battery Junction Box Page 2961 Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 2093 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. With the vehicle in NEUTRAL, position it on a hoist. 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 bearing must be installed. Safety Belt System Seat Belt Tensioner: Description and Operation Safety Belt System Safety Belt Buckle Pretensioner - All vehicles The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the safety belt when deployed. The pretensioner works in conjunction with the front air bag system. When the front air bags deploy, the pretensioners deploy, causing the buckle to move downward, removing excess webbing from the lap and shoulder safety belts. If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt pretensioners, a new driver and passenger seat belt system (including safety belt buckle and pretensioners, safety belt retractors, and height adjusters), must be installed. For safety belt buckle pretensioner diagnostic information, refer to Air Bag Systems. For safety belt buckle pretensioner disposal information, refer to Air Bag Systems. Belt Tension Sensor (BTS) The safety belt tension sensor (BTS) is part of the passenger front outboard safety belt and retractor assembly. The BTS is located at the safety belt anchor point and is used in conjunction with the occupant classification sensor (OCS) system. Page 5791 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Testing and Inspection Ignition Relay: Testing and Inspection Page 2895 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Page 3222 Throttle Position Sensor: Diagrams Page 7240 Page 6950 The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat and depower the SRS. 2. Using a small flat-blade screwdriver, release the locking tab and slide the heated seat module off the bracket. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. 4. Install the front seat and repower the SRS. Page 6576 Front Door Panel: By Symptom Technical Service Bulletin # 06-9-2 Date: 060515 Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION BASIC PART NO. CODE 78237A05 12 P0125 P0125 Page 1569 Page 1502 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Page 3056 Page 7222 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. Liftgate Ajar Switch Page 6320 Navigation System: Service and Repair NAVIGATION SYSTEM CALIBRATION 1. Access the current set of regional map compact discs (CDs). 2. Start the vehicle. 3. Turn the audio unit on. 4. Insert the appropriate regional map CD into the CD slot at the top of the audio unit. 5. Press the NAV button. 6. Press ACCEPT after reading the disclaimer. 7. Press the MAP button. 8. Road test the vehicle until the red compass heading indicator turns green/white. 9. Leave the CD in the audio unit. Page 7803 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 Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Material Page 6215 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the electrical connectors. 3. Remove the 2 screws and the parking aid module. 4. To install, reverse the removal procedure. Page 7915 View 151-22 (Left Front Door) Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the heated oxygen sensor (HO2S) electrical connector. 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: System Diagnosis P0815 Page 6212 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 7496 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 4525 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Front Wheel Speed Sensor Ring-Front Removal and Installation 1. The front wheel speed sensor ring is integral to the front halfshaft and cannot be repaired separately. Page 4200 12. Using a soft face hammer, install the halfshaft on the inner CV joint. 13. Position the inner halfshaft boot. 14. Remove any excess air trapped in the inner halfshaft boot using a cloth-covered screwdriver after adjusting the inner halfshaft boot spacing. 15. Using the special tool, install 2 new inner CV joint boot clamps. 16. Install the halfshaft. Page 3922 6. Remove the shifter. 1 Disconnect the electrical connector. 2 Remove the 4 bolts and remove the shifter. Installation 1. Install the shifter assembly. 1 Install the shifter and the 4 bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 2 Connect the electrical connector. 2. Install the upper center console assembly. Page 3225 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Engine Controls - Long Crank/Hard Start PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Long Crank/Hard Start TSB 05-26-1 12/31/05 LONG CRANK/HARD START - 3.0L FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2005-2006 Escape and Mariner 3.0L vehicles built from 7/19/2004 through 12/5/2005 may exhibit a long crank/hard start under either cold or hot engine conditions. ACTION Reprogram the powertrain control module (PCM) using WDS release B40.4 and higher or B41 .1 and higher. This new calibration is not included in the B41 CD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 052601A 2005-2006 Escape/Mariner 0.4 Hr. 3.0L Engine: Check For Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do not use with 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Page 2887 Page 3901 Shift Interlock: Description and Operation Shift Interlock System The shift interlock system prevents the gear shift lever from being moved out of the PARK (P) position. The ignition switch must be in the ON position and the brake pedal depressed to move the gearshift lever out of the PARK position. The brake pedal position is detected by the Brake Pedal Position (BPP) switch. The manual override button will mechanically bypass the electronic portion of the shift interlock system and allow the gearshift lever to be moved out of the PARK position. The manual override button is part of the gearshift lever assembly. To override the brake shift interlock, remove the tethered cap on the gear shift bezel with a small screwdriver. With the brake pedal depressed, insert a small screwdriver into the access hole, press down and pull the gear shift lever out of PARK. Page 295 P0450 - P0454: Testing and Inspection P0453 P0453 (Part 1) P0453 (Part 2) Page 5524 Removal and Installation 1. Remove the center register duct. 2. Remove the 2 passenger side register nuts and the passenger side register. 3. To install, reverse the removal procedure. Page 5505 Removal and Installation 1. Remove the driver and front passenger seats. 2. Remove the floor console. 3. Remove the front door scuff plate trim panels and the lower A-pillar trim panels. 4. Pull back the carpeting to gain access to the floor ducts. 5. Separate the wiring harness from the floor ducts and position aside. 6. Remove the floor duct. 7. To install, reverse the removal procedure. CENTER REGISTER DUCT Page 6158 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Page 4815 Testing and Inspection Vacuum Brake Booster Check Valve: Testing and Inspection Check Valve 1. Remove the vacuum booster hose from the power brake booster. 2. Apply 57.3 kPa (17 in-Hg) of vacuum to the vacuum booster hose. If the vacuum does not leak off after 10 minutes, the check valve is OK. Otherwise, install a new check valve. Page 6811 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 5065 Page 2438 View 151-3 (Engine Compartment, 1 Of 2) Page 2181 Engine Block Heater: Service and Repair Block Heater Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Drain the cooling system. 4. CAUTION: Make sure that the block heater wiring is routed and secured away from rotating or hot components, or damage to the wiring can occur. Disconnect the block heater electrical connector. 5. Remove the block heater. ^ To install, tighten to 21 Nm (15 ft. lbs.). 6. To install, reverse the removal procedure. 7. Fill and bleed the cooling system. Page 335 P0533 Locations Page 3667 Page 7990 Page 4871 Power Distribution Relay: Testing and Inspection Page 4672 Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity....................................................................................................................................... ..........................................................9.5L (10 quarts) Page 1104 Page 679 P1567 Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Page 3570 Air Flow Meter/Sensor: Diagrams Service and Repair Maintenance Required Lamp/Indicator: Service and Repair ENGINE OIL CHANGE SOON/ENGINE OIL CHANGE NOW Displayed when the engine oil life remaining is 5% or less. When oil life left is between 5% and 0%, the ENGINE OIL CHANGE SOON message will be displayed. When oil life left reaches 0%, the ENGINE OIL CHANGE NOW message will be displayed. An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 12 months] perform the following. 1. Press the SET control to access the system check function. 2. Press and release the SET control to display "OIL CHNG XXX% HOLD SET NEW". 3. Press and hold the SET control for 2 seconds to display "OIL CHANGE SET TO 100%". Page 3771 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Locations Page 2984 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 Specifications Brake Fluid: Specifications Brake Fluid Type .......................................................................................... Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 1464 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Service and Repair Air Duct: Service and Repair DEFROSTER DUCT Removal and Installation 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 2. Remove the 4 side window demister nuts and both side window demisters. 3. Remove the 3 defroster duct screws and the defroster duct. 4. To install, reverse the removal procedure. FLOOR DUCT Page 7236 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 Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... .......................................................... 680 - 750 RPM Page 789 P2107 Page 5750 Page 7923 Page 1384 Specifications Piston Pin: Specifications Piston Pin Diameter .............................................................................................................................................. .................... 20.995-21.0 min (0.8266-0.8268 in.) Length .................................................................. ............................................................................................................ 59.6-60.4 min (2.346-2.377 in.) Piston-to-pin clearance ............................................................................................................................................ 0.008-0.016 min (0.0003-0.0006 in.) Pin-to-rod clearance .................................................................. ............................................................................................................................ Press fit Page 3005 D1-D2 Normal Operation The 4WD control module communicates with the diagnostic tool through the high speed CAN communications network, circuits 1908 (WH) and 1909 (BK). If one of the bus wires becomes shorted to ground or voltage, communication can continue at a reduced level. Check circuits 1908 (WH) and 1909 (BK) between the 4WD control module C3253 and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the high speed CAN circuits, damage to the DLC C251, damage to the 4WD control module C3253, or a problem in an in-line connector. Possible Causes - high speed CAN circuits 1908 (WH) and 1909 (BK) open - DLC C251 - 4WD control module C3253 - 4WD control module Test E: The Parking Aid Module Does Not Respond to The Diagnostic Tool PINPOINT TEST E: THE PARKING AID MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Page 5573 4. Remove the A/C clutch pulley snap ring. 5. Remove the A/C clutch pulley. 6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Using the special tools, remove the A/C clutch field coil. Installation 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. NOTE: Position the A/C clutch field coil on the A/C compressor as previously marked. Page 3601 Throttle Position Sensor: Diagrams Page 5496 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 auxiliary line floorpan bracket nuts. To install, tighten to 6 Nm (53 lb-in) 3. NOTE: The D-pillar bracket mill remain in place. Remove the LH D-pillar trim panel. See: Body and Frame/Interior Moulding / Trim 4. NOTE: When installing, tighten the screws on the High voltage Traction Battery (HVTB) first to make sure the duct is sealed correctly. Remove the 4 battery airflow duct screws, the 1 pin-type retainer and the battery airflow duct assembly To install, tighten 12 Nm (18 lb-in) 5. Remove the 2 auxiliary climate control fresh air inlet duct nuts ^ To install tighten to 7 Nm (62 lb-in). 6. Remove the 2 auxiliary climate control housing bolts. ^ To install tighten to 7 Nm (62 lb-in). 7. Remove the D-pillar bracket pin-type retainer. 8. Remove the D-pillar bracket upper pin-type retainer and bolt end remove the D-pillar bracket. 9. Disconnect the auxiliary airflow mode door actuator electrical connector Page 3409 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Flow and Leakage ...................................................................................... Refer to Pinpoint Test HC13 at Computers and Control Systems. Page 7514 A1-A4 Page 7618 Symbols Part 2 Page 6613 - Lubricate the rear door latch to striker surfaces after installation. Page 7232 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 7139 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open 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. Initial Inspection and Diagnostic Overview Courtesy Lamp: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The smart junction box (SJB) supplies voltage and ground to the interior lighting system. The interior lighting system illuminates the interior lamps to enhance visibility of the interior while a vehicle door is open or ajar, and the vehicle speed is lower than 15 km/h (9 mph). The SJB controls all interior lighting functions and timing by monitoring inputs from the door ajar switches, liftgate ajar switch, liftgate glass ajar switch and vehicle speed. Interior Lighting Delay The purpose of the interior lighting delay feature is to provide temporary illumination of the interior lamps after doors are opened, then closed. The interior lighting delay feature will keep the interior lamps on for a period of up to 25 seconds, or until the ignition cycles from OFF, or the vehicle is locked using the remote keyless entry (RKE) transmitter. Illuminated Entry The illuminated entry requests the interior lamps to be illuminated when the ignition is off and the RKE transmitter unlock button is pressed. The illuminated entry requests the interior lamps off after 25 seconds elapse, the ignition is switched to ON, or when the RKE transmitter lock is pressed. Illuminated Exit The illuminated exit requests the interior lamps be illuminated for 25 seconds when all doors are closed and the ignition key is removed from the ignition lock cylinder. The illuminated exit will request the interior lamps be deactivated when any door becomes ajar, the key is inserted into the ignition lock cylinder, or 25 seconds expire. Theater Lighting The theater lighting option ramps up the interior lamps over 0.7 seconds when interior lamp activation is requested. The theater lighting feature ramps down the interior lamps over 1.7 seconds when interior lighting deactivation is requested by any other feature other than the panic alarm or battery saver. Interior Lamp Arbitrator The interior lamp arbitrator (located in the SJB) chooses between the interior lighting, interior mode, interior lighting delay, illuminated entry, illuminated exit and battery saver to determine which feature has precedence of activating and deactivating the interior lamps. The features are prioritized as follows: battery saver, interior mode, interior lighting, interior light delay, illuminated entry, and illuminated exit. Battery Saver The battery saver is internal to the SJB and provides automatic shut-off of the demand lamps (vanity lamps and map lamps) and interior lamps after a period of 10 minutes has elapsed in order to save battery voltage. A timer in the SJB is started when the ignition key is turned to the OFF position. When the time-out period for the lamps has elapsed, the voltage is automatically shutoff to the lamps by the battery saver. While battery saver has voltage disabled, if the ignition is turned to any position other than OFF, any door or liftgate becomes ajar or the unlock button of the remote transmitter is pressed, the battery saver will restore voltage and start the timer again. The amount of time that is required to elapse before the voltage to the lamps is shut off is 10 minutes. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. Visual Inspection Chart Page 7242 44-2 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 1999 Page 7398 Mechanical Returnless Fuel Pump Module (FPM) Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 2855 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Page 1488 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the RH lower A-pillar trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. P0355 P0355 P1537 P1537 Page 3083 7. Remove the SJB screw. 8. Disconnect the electrical connectors and remove the SJB. 9. To install, reverse the removal procedure. - Configure the SJB. Refer to Information Bus (Module Communications Network). Page 6023 Seat Belt Height Adjuster: Service and Repair Safety Belt Shoulder Height Adjuster SAFETY BELT SHOULDER HEIGHT ADJUSTER Removal and Installation WARNING: All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. NOTE: The passenger side safety belt shoulder height adjuster is shown, the driver side is similar. 1. Remove the B-pillar trim panel. Page 2432 7. To install, reverse the removal procedure. 8. Fill and bleed the cooling system. Page 7801 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 99 P0153 Left Front Page 2011 Page 462 P1114 Page 4852 Page 6501 Symbols Part 4 Page 7893 Front Wheel Fastener: Service and Repair Front Wheel Studs Removal and Installation 1. Remove the wheel bearing and hub. 2. Using a suitable press, remove the wheel stud from the wheel hub. 3. To install, reverse the removal procedure. Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking Points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Drivetrain - Fluid leak From PTU Vent Fluid - Transfer Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Page 2706 Page 7290 B1212-B1243 Page 5600 Condenser HVAC: Service and Repair CONDENSER CORE Removal and Installation NOTE: - Installation of a new suction accumulator is not required when repairing the air conditioning (A/C) system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. - If a condenser core leak is suspected, the condenser core must be leak tested before it is removed from the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the refrigerant. 3. Remove the front bumper cover. 4. Remove the 2 condenser core peanut fitting nuts. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the 4 condenser core bracket bolts and the 2 condenser core brackets. - To install, tighten to 9 Nm (80 lb-in). 6. Remove the condenser core. 7. NOTE: A new O-ring seal lubricated with clean mineral oil must be installed before installing a new switch. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of PAG oil. - Evacuate, leak test, and charge the refrigerant system. Page 7002 Page 2930 Page 7520 C1-C3 Page 2890 Brake Signal: Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open 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. System Diagnosis P079x Page 1534 Impact Sensor: Description and Operation 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 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. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have a front impact severity sensor and it is located in the front-center of the vehicle, mounted on the radiator support bracket. If the vehicle is equipped with safety canopies, there are 4 additional side impact sensors. The 4 additional sensors are located at the base of each B-pillar and mounted on the C-pillar. The LH and RH C-pillar mounted side impact sensors are interchangeable. Mounting orientation is critical for correct operation of all impact and rollover sensors. Page 4458 Locations View 151-12 (Dash Panel) Page 5704 Condenser Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Remove the RH splash shield. 5. If equipped, disconnect the block heater electrical connector. 6. Remove the compressor to condenser discharge line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the compressor to condenser discharge line from the compressor. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the condenser core peanut fitting nut and disconnect the condenser core peanut fitting compressor. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor to condenser discharge line. 10. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Connector Views Control Assembly: Connector Views Page 1299 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH Removal and Installation 1. NOTE: The fog lamp switch is removed by pushing from behind. Remove the fog lamp switch from the instrument panel. Disconnect the fog lamp switch electrical connector. 2. To install, reverse the removal procedure. Page 5105 Alignment: Service and Repair Toe Adjustment Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off. Hold the steering wheel in the straight-ahead position using a suitable holding device. 3. Check the toe settings following the equipment manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Page 2302 Intake Manifold: Service and Repair Intake Manifold Rear Door Handles, Locks and Latches - Exploded View Rear Door Latch: Service and Repair Rear Door Handles, Locks and Latches - Exploded View REAR DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 2481 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. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 776 P2072 Page 4612 Brake Bleeding: Service and Repair Manual Bleed Manual Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, to the RH front wheel, and ending with the LH front wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until the fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 8. Continue bleeding the brake hydraulic system at each wheel. 9. Fill the brake master cylinder reservoir with the specified brake fluid. Service and Repair Antenna, Navigation: Service and Repair GLOBAL POSITIONING SYSTEM (GPS) ANTENNA Removal and Installation 1. Disconnect the battery. 2. Remove the audio unit. 3. Remove the GPS antenna bolt and the GPS antenna. 4. To install, reverse the removal procedure. Page 5908 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 (ECU), 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 Page 5756 Compressor Clutch Relay: Description and Operation AIR CONDITIONING CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. 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 communications network). 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 A/CCR output, closing the relay contacts and sending voltage to the A/C clutch. Page 5021 Page 7523 E1-E2 Normal Operation Circuit 1005 (VT/OG) provides voltage to each interior lamp when activated. The interior lamps are grounded through circuit 401 (PK). The battery saver in the SJB deactivates the voltage and ground circuits after time-out. Possible Causes - circuit 1005 (VT/OG) open - circuit 401 (PK) open - lamp assembly Test F: The Illuminated Entry Is Inoperative When Using The Remote Keyless Entry (RKE) Transmitter PINPOINT TEST F: THE ILLUMINATED ENTRY IS INOPERATIVE WHEN USING THE REMOTE KEYLESS ENTRY (RKE) TRANSMITTER F1 Page 3542 Main Relay (Computer/Fuel System): Testing and Inspection Specifications Brake Caliper: Specifications Brake caliper anchor plate ................................................................................................................... ................................................. 150 Nm (111 ft. lbs.) Brake caliper guide bolts (disc-drum system) ........................................................................................................................................... 35 Nm (26 ft. lbs.) Brake caliper guide bolts (4-wheel disc brake system) ............................................................................................................................. 45 Nm (33 ft. lbs.) Brake caliper jounce hose (at caliper) ...................................................................................................................................................... 20 Nm (15 ft. lbs.) Smart Junction Box Fuse: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 1014 Air Bag Control Module: Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Adjustments Rear Door Striker: Adjustments STRIKER ADJUSTMENT NOTE: Before adjusting the door latch striker plate, verify that the door can be closed easily and fits tightly. 1. Loosen the door latch striker bolts. 2. Reposition the door latch striker plate from side to side or up and down as necessary. 3. Tighten the door latch striker plate bolts. 4. NOTE: The rear door is shown, the front door is similar. Check the adjustment. Repeat the procedure as necessary. Page 4416 1. NOTE: Clean the inside of the driven gear of foreign material prior to installation. Using the special tools, install the transfer case inner halfshaft seal. 2. Install the transfer case. Page 3924 Shifter A/T: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. Page 7256 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 7545 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Testing and Inspection Mini ISO Relay: Testing and Inspection Page 1211 2 Connect the electrical connector. 4. NOTE: There should be an extra click heard when tugging on the brake pedal. Slowly release the brake pedal and tug moderately once the pedal reaches the rest position. Page 6466 Symbols Part 5 Page 6053 assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. 1. Remove the 60 percent seat backrest. 2. Remove the bolt and the LH riser bracket. - To install, tighten to 55 Nm (41 lb-ft). 3. Remove the bolt and the RH riser bracket. - To install, tighten to 55 Nm (41 lb-ft). 4. Remove the head restraints. 5. Remove the 2 screws and the latch cover. 6. Remove the 2 seat latch release cover screws. 7. Remove the seat latch release lever. 1 Detach the latch rod from the seat latch release lever. 2 Remove the seat latch release lever. 8. Remove the 2 screws and the safety belt shield. 9. Release the backrest trim cover J-clip. General Procedures Lifter / Lash Adjuster: Service and Repair General Procedures Valve Tappet Inspection 1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident, inspect the camshaft lobes and valves for damage. 2. Replace components as necessary. Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 6859 C. Drill the hole at a slow to moderate pace, occasionally pulling the bit out to clear the chips. D. Drill the hole to the proper depth using the stop on the bit as your depth gauge. See Figure 6. E. Drill the second hole in the same foam block in the same manner. F. Repeat steps A - E on the foam block on the other side of the headliner. 5. Remove the covers from the instrument panel and clean all foam chips from the vehicle. Proceed to ASSEMBLY. ASSEMBLY 1. Position the B-pillar trim panels and install the bolts. Tighten to 7 Nm (62 lb-in), then install the bolt covers. 2. Position the safety belt and install the safety belt bolts at the B-pillar. Tighten to 53 Nm (39 lb-ft), then install the D-ring covers. 3. Install the A-pillar trim panels. 4. Install the passenger A-pillar assist handles and bolts. Tighten to 5 Nm (44 lb-in), then install the bolt covers. 5. Install the front and rear door weatherstrips. 6. Connect and install the overhead console, if equipped. 7. Install and connect the interior lamp and screws. 8. Install the interior lamp lens. 9. Install the sunvisors, connecting the electrical connectors if equipped, and the sunvisor clips. 10. Install the rear seat overhead assist handles and bolts. Tighten to 8 Nm (71 lb-in), then install the bolt covers. Owner Letter Owner Notification Letter will be mailed on May 19, 2006. Page 7874 Heated Glass Element Relay: Testing and Inspection System Diagnosis P0210 Specifications Brake Shoe: Specifications Brake Shoe Thickness Minimum .............................................................................................................................................. ...................................................... 1mm (0.03 in.) Page 6796 All Vehicles 7. NOTE: On Escape, if removing the floor console storage bin, squeeze the front and rear of the storage bin to release the retaining tabs from the floor console finish panel. Remove the floor console finish panel. Disconnect the electrical connectors. 8. Remove the 6 bolts and remove the floor console. 9. To install, reverse the removal procedure. Page 1813 Heater Hose: Service and Repair HEATER HOSE Heater Hose To Heater Core Connections Locations P1460 P1460 Page 5664 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 4237 Flex Plate: Service and Repair Flexplate Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the automatic transaxle. 3. Remove the 6 bolts and the flexplate. Installation 1. NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flexplate and tighten the bolts in the sequence shown in 3 stages. ^ Stage l: Tighten to 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten to 80 Nm (50 ft. lbs.). ^ Stage 3: Tighten to 112 Nm (83 ft. lbs.). 2. Install the automatic transaxle. Page 6244 Page 252 P0357 Page 7814 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 3037 Page 4152 4. Line up the index marks and install the rear driveshaft universal joint. ^ Install the 2 cap straps and the 4 bolts. ^ Tighten to 23 Nm (17 ft. lbs.). Page 612 P1451 Page 7786 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 2441 Radiator Cooling Fan Motor: Description and Operation FAN CONTROL Five Hundred/Freestyle/Montego, Crown Victoria/Grand Marquis, Town Car: FCV Duty Cycle Output From PCM (negative Duty Cycle) LS, 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) 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. Some applications will have the xFC circuit wired to 2 separate relays. Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................. 1.25 - 1.35mm (0.049 - 0.053 in.) Spark Plug Tightening Torque ............................................................................................................. ........................................................ 12 Nm (9 lb.ft.) Electrical Specifications Alternator: Electrical Specifications ITEM..................................................................................................................................................... ...................................................SPECIFICATION Battery Voltage................................................................................................................................................. ........................................................................12 volts Generator Rating..............................................................................................75/120 amp (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm No Load at 2000 rpm................... .....................................................................................................................................................betw een 13.0 - 15.0 volts Load at 2000 rpm................................................................................................ ........................................................................................................75 amps. A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 3558 Page 6153 Seat Sensor/Switch: Locations Seat Belt Buckle Sensor View 151-20 (Driver Seat) Page 5839 Air Bag Control Module: Diagrams Liftgate Ajar Switch View 151-25 (Liftgate) Page 5706 To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Disconnect the high pressure cut-off switch electrical connector. 5. Remove the condenser to evaporator line bracket nut. - To install, tighten to 8 Nm (71 lb-in). 6. Disconnect the evaporator core spring lock coupling. 7. Remove the condenser to evaporator line peanut fitting nut and disconnect the line. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the condenser to evaporator line. 9. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Page 1973 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 2133 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes necessary to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. Page 6715 6. Remove the power steering hose bracket bolt. - To install, tighten to 10 Nm (89 lb-in). 7. Using the special tool, support the engine. 8. Remove the bolts and the lateral support crossmember. - To install, tighten to 115 Nm (85 lb-ft). 9. Remove the splash shield bolt. 10. Remove the front insulator bolt. - To install, tighten to 115 Nm (85 lb-ft). 11. Remove the 2 engine support crossmember bolts. - To install, tighten to 90 Nm (66 lb-ft). 12. Remove the nut and the engine support crossmember. - To install, tighten to 175 Nm (129 lb-ft). 13. Remove the 2 lower control arm ball joint pinch bolt and nuts. - To install, tighten to 70 Nm (52 lb-ft). 14. Remove the 2 nuts and disconnect the 2 stabilizer bar links. - To install, tighten to 47 Nm (35 lb-ft). 15. Remove the 2 steering gear bolts. - To install, tighten to 115 Nm (85 lb-ft). 16. Position the steering gear out of the subframe mounts. 17. Remove the exhaust flexible pipe (2.3L) or the dual converter Y-pipe (3.0L). 18. If equipped with 4WD, remove the driveshaft. 19. NOTE: The engine must be lowered to allow the front subframe to clear the transaxle companion flange. If equipped with 4WD, use the special tool to lower the rear of the engine approximately 150 mm (5.9 in). 20. NOTE: - Do not allow the front subframe rear bolts to come out of the lower control arm bushing. - When installing the front subframe rear bolts, make sure both of the front subframe rear bolts are fully engaged in their cage nuts before tightening to specification. Loosen the 2 front subframe rear bolts. Page 4516 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 4623 Brake Caliper: Service and Repair Caliper Disassembly and Assembly, Rear Brake Caliper Material Material 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 the surface with water Disassembly and Assembly 1. Remove the brake caliper. 2. Secure the brake caliper in a vise. 3. Remove the brake caliper dust boot. 4. Remove the bleeder screw cap. 5. Remove the bleeder screw. ^ To install, tighten to 16 Nm (12 ft. lbs.). Page 4131 1. Lightly lubricate the shifter straw with multi-purpose grease, and install it into the shifter bore by pushing straight down. 2. Feed the overdrive cancel switch electrical connector wire harness into the opening in the dash and install the knob. 3. Install the set screw. 4. Connect the overdrive cancel switch electrical connector. 5. Install the top finish panel. Page 7665 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 2284 Smart Junction Box Fuse Block: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. A/T - Engine Stall Upon Gear Engagement Torque Converter: All Technical Service Bulletins A/T - Engine Stall Upon Gear Engagement TSB 07-5-6 03/19/07 CD4E - ENGINE STALLING ON ENGAGEMENT/STOPPING FORD: 2005-2008 Escape MERCURY: 2005-2008 Mariner ISSUE Some 2005-2008 Escape and Mariner vehicles equipped with a CD4E automatic transaxle and built from 8/1/2004 through 2/15/2007 may exhibit an engine stall when coming to a stop or when engaging the transmission into drive or reverse. This condition may be intermittent and often occurs after extended drives. There may be no diagnostic trouble codes (DTCs) stored. This may be caused by internal wear in the torque converter which prevents it from unlocking. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect and repair all non transaxle codes per Workshop Manual (WSM) and Powertrain Controls/Emissions Diagnosis (PC/ED) manuals. 2. Use the Integrated Diagnostic System equipment to monitor the PIDs (Parameter Identification) for TC_SLIPACT as the stall is occurring. a. If the slip is greater than 20 RPM, the stalling is not transaxle related. Repair following PC/ED procedures for engine stalling condition. b. If TC_SLIPACT is less than 20 RPM with the transmission in park or neutral, torque converter internal failure is the most likely cause, proceed to Step 3. 3. Remove the transaxle assembly and check the rotation of the torque converter in the bell housing. A failed converter will be difficult to rotate. 4. Remove the torque converter, drain the automatic transmission fluid (ATF) and refill the CD4E transmission assembly using MERCON(R) V ATF. 5. Install a new torque converter and reinstall the transaxle assembly. 6. Back flush the transmission cooler system as described in the WSM, Section 307-01A. 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 070506A 2005-2008 Escape/Mariner 5.2 Hrs. 4X2 2.3L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, Page 5793 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Service and Repair Valve Guide Seal: Service and Repair Valve Seals Special Tool(s) Material Removal 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. Service and Repair Evaporator Case: Service and Repair EVAPORATOR CORE HOUSING Removal and Installation 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 contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. Remove the instrument panel. 3. Disconnect the vacuum hose. 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: Diagrams Page 857 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Diagrams Clockspring Assembly / Spiral Cable: Diagrams Page 5187 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... .......................................................... 680 - 750 RPM Page 4378 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Page 6810 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Front Wheel Bearing: Service and Repair Front Wheel Bearing and Wheel Hub Page 592 P1401 Page 58 P0115 - P0119: Testing and Inspection P0118 P0118 (Part 1) P0118 (Part 2) Page 7413 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 7237 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 2457 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 2771 View 151-8 (Engine, rear) Page 6349 Speaker: Service and Repair Speaker Enclosure SPEAKER ENCLOSURE Removal and Installation 1. Remove the RH quarter trim panel. 2. Disconnect the subwoofer amplifier electrical connector. 3. Remove the 3 bolts and the speaker enclosure. - To install, tighten to 8 Nm (71 lb-in). 4. To install, reverse the removal procedure. Page 3897 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. Locations View 151-7 (Engine, front) Service and Repair Valve Seat: Service and Repair Valve Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. ^ If out of specification, install new components as necessary. Valve Inspection 1. Inspect the following valve areas: 1. The end of the stem for grooves or scoring 2. The valve face and the edge for pits, grooves or scores 3. The valve head for signs of burning, erosion, warpage and cracking 4. The valve margin for wear Valve Seat Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. ^ Check valve angles. ^ Check margin width. ^ Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found. System Diagnosis P0167 Page 4483 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 597 P1406 Service and Repair Oil Separator: Service and Repair CRANKCASE VENT OIL SEPARATOR Exploded View Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the intake manifold. 3. Remove the 8 bolts and the crankcase vent oil separator. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Clean the engine block mating surface. Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side P0131 P0131 Page 246 P0354 Page 1364 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 3898 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 3059 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater by providing the ground when the proper conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 7697 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. Diagrams Page 7816 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 667 P1538 Page 579 P1381 Page 2304 9. Disconnect the swirl control valve electrical connector. 10. Disconnect the knock sensor (KS) electrical connector. ^ Detach the electrical connector pin-type retainer. 11. Disconnect the temperature manifold absolute pressure (TMAP) sensor electrical connector. 12. Disconnect the oil pressure sender electrical connector. ^ Detach the wiring harness pin-type retainer and position the wiring harness aside. 13. NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure they are installed in the correct location. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube. ^ To install, tighten to 18 Nm (13 ft. lbs.). 14. Release the clamp and disconnect the crankcase vent hose. 15. Remove the exhaust gas recirculation tube. ^ To install, tighten to 55 Nm (41 ft. lbs.). 16. Remove the intake manifold and gaskets. 17. To install, reverse the removal procedure. ^ Inspect and install new intake manifold gaskets if necessary. Page 972 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the powertrain control module (PCM) stud bolt nut and position the wiring harness aside. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the 3 PCM electrical connectors. 4. Remove the stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the PCM cowl seal. 6. To install, reverse the removal procedure. Page 5353 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 6438 Symbols Part 2 Page 3991 3. Remove the intake tube and air cleaner cover. 4. Remove the air cleaner assembly. 5. Remove the mount through bolt. ^ To install, tighten to 120 Nm (89 ft. lbs.). 6. Remove the 1 retaining bolt and the 2 nuts for the mount and remove the mount. ^ To install, tighten to 90 Nm (66 ft. lbs.). 7. To install, reverse the removal procedure. Page 4957 Page 2671 Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 5728 1. Connect an R-134a refrigerant center to the low pressure and high pressure 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 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again. Refrigerant System Evacuation Using an R-134a Manifold Gauge Set NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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 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 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 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 Refrigerant Center NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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 center to the low-side and high-side 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: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system 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 6880 4. Disconnect the lock cylinder actuating rod and separate the front door latch from the exterior door handle reinforcement. 5. Remove the door lock cylinder. 1 Release the clips. 2 Remove the lock cylinder. 6. To install, reverse the removal procedure. Page 5930 12. Install the manual lumbar control knob. All seats 13. Connect the side air bag electrical connector and attach the wiring retainers. 14. Tighten the safety belt buckle pretensioner bolt. - Tighten to 40 Nm (30 lb-ft). 15. Install the inboard seat cushion side shield and screw. 16. Install the front seat and repower the system. Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 5983 Child Seat Tether Attachment: Service and Repair CHILD SAFETY SEAT TETHER ANCHOR Removal and Installation WARNING: All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. 1. Remove the child safety seat tether anchor cover by releasing the top anchor end of the cover first and rocking the cover off of the anchor bolt end. Page 5217 Steering Wheel: Service and Repair Steering Wheel Removal and Installation 1. Position the steering wheel in the straight-ahead position and remove the ignition key. ^ Rotate the steering wheel until the steering column locks into position. 2. Depower the Supplemental Restraint System (SRS). Refer to Air Bag Systems. 3. Open the cover on the underside of the steering wheel. 4. Remove the steering wheel pinion bolt. ^ To install, tighten to 12 Nm (9 ft. lbs.). 5. Remove the steering wheel. 1 Position the steering wheel rearward. 2 Disconnect the 2 electrical connectors. 6. To install, reverse the removal procedure. ^ Repower the Supplemental Restraint System (SRS). Refer to Air Bag Systems. Page 4826 Specifications Camshaft Bearing: Specifications Camshafts and bearing caps. Tighten the bolts in the sequence shown in 3 stages: Stage 1: Tighten the camshaft bearing cap bolts one at a time until finger tight. Stage 2: Tighten to . .............................................................................................................................................................. ....... 7 Nm (62 inch lbs.). Stage 3: Tighten to ...................................................................................... .................................................................................. 16 Nm (12 ft. lbs.). Page 4032 12. Connect the transaxle wiring harness electrical connector and the Transmission Range (TR) sensor electrical connector. 13. Install the intake tube and the air cleaner cover. 14. Install the breather tube and connect the Mass Air Flow (MAF) sensor electrical connector. 15. Install the battery tray. 16. Fill the transaxle with clean automatic transmission fluid. 17. Start the engine and run through all the gears and check fluid level. Page 3921 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Remove the shift cable from the gearshift assembly. 1 Disconnect the shift cable end from the gearshift lever. 2 Remove the shift cable from the bracket. Page 2546 If installing a new converter, install the HO2S and the catalyst monitoring sensor using the special tool. ^ Tighten to 47 Nm (35 ft. lbs.). 5. Connect the H02S and the catalyst monitoring sensor electrical connectors. 6. Position the heat shield and install the 6 heat shield bolts. ^ Tighten to 10 Nm (89 inch lbs.). 7. Install the 2 catalytic converter bracket bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 8. Install the exhaust flexible pipe. Page 1127 Page 7689 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. Fuel Pump Module and Reservoir Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 5901 View 151-21 (Passenger Seat) Page 7034 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 3433 Page 7566 Service and Repair Accumulator HVAC: Service and Repair SUCTION ACCUMULATOR Removal and Installation NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning (A/C) system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. 2. Disconnect the A/C cycling switch electrical connector. 3. Disconnect the evaporator core outlet tube spring lock coupling and the A/C compressor manifold and tube spring lock coupling. 4. Remove the 2 suction accumulator bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 5. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of PAG oil. - Evacuate, leak test, and charge the refrigerant system. Page 5437 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) System Diagnosis P0161 Page 7456 Smart Junction Box (SJB) C2280c Stoplamp Switch C278 Test J: The Stoplamps Are Inoperative PINPOINT TEST J: THE STOPLAMPS ARE INOPERATIVE Page 1557 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Page 7736 Page 5823 13. Lift to unhook the safety canopy module from the C-pillar. 14. Move the safety canopy module forward and release the rear hook. Installation 1. Install new safety canopy module J-nuts. Page 4078 10. To install, reverse the removal procedure. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. ^ Adjust the shift cable after installation. Page 2784 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Locations View 151-12 (Dash Panel) Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 2452 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 3098 Page 1601 Page 1356 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 6179 Alarm System Transponder: Service and Repair PASSIVE ANTI-THEFT SYSTEM (PATS) TRANSCEIVER Removal and Installation 1. Remove the instrument panel steering column cover. 2. Remove the ignition lock cylinder. 3. Remove the 3 steering column shroud screws and the lower steering column shrouds. 4. Remove the PATS transceiver screw. 5. Disconnect and remove the transceiver assembly electrical connector. 6. NOTE: No key replacement or re-initialization needs to occur with the removal or installation of a new PATS transceiver. To install, reverse the removal procedure. Page 6634 3. Install the hood latch nut. - Tighten to 9 Nm (80 lb-in). Page 919 Locations View 151-7 (Engine, front) Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Bleeding, Components Brake Bleeding: Service and Repair Bleeding, Components Brake System Bleeding Special Tool(s) Material Anti-Lock Brakes Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: Bleeding the hydraulic control unit (HCU) is required only when removing or installing the HCU, master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 diagnostic tool cycles and 2 manual bleed cycles. Page 2614 Page 7202 Symbols Part 2 Service and Repair Muffler: Service and Repair Muffler Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 exhaust catalytic converter nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 3. Remove and discard the U-bolt clamp assembly from the muffler. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Remove and discard the 2 resonator nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 5. Remove and discard the catalytic converter exhaust hanger. 6. Remove the exhaust catalytic converter and the muffler from the vehicle as an assembly. 7. Separate the muffler from the catalytic converter. 8. To install, reverse the removal procedure. ^ Install new gaskets. Service and Repair Door Lock Cylinder: Service and Repair DOOR LOCK CYLINDER Removal and Installation NOTE: 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 latch. 2. Remove the 3 screws and position the anti-theft guard aside. 3. Open the clip and disconnect the exterior door handle actuating rod. Page 3378 Accelerator Pedal: Service and Repair ACCELERATOR PEDAL AND SHAFT Removal and Installation 1. Remove the accelerator cable from the rubber plunger. 2. Position the plunger rearward and remove the cable from the accelerator pedal. 3. Remove the 2 bolts and the accelerator pedal and shaft assembly. Adjustments Parking Brake Cable: Adjustments Parking Brake Cable Adjustment 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. ^ Pull the parking brake control boot up and over the lever. 2. Turn the parking brake control adjustment nut to adjust the parking brake control stroke. ^ Adjust the parking brake control until the parking brake control stroke is 5 notches when pulled. 3. Verify the parking brake is applied. 4. Install the parking brake control boot. Page 5045 Relay Box: Diagrams Smart Junction Box (SJB) Page 5729 Refrigerant: Service and Repair Refrigerant Identification Testing REFRIGERANT IDENTIFICATION TESTING 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 1 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 the 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 the hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, Hydrocarbon High 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 the 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 386 P0663 Description and Operation Fuel Pump Signal: Description and Operation Fuel Pump Monitor (FPM) Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control The FPM circuit is spliced into the fuel pump power (FP PWR) circuit and is used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also confirms that the FP PWR or FPM circuits are not 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 (FPDM) Applications Fuel Pump Driver Module Duty Cycle Signals NOTE: The Ford GT uses 2 FPDMs to control fuel for the dual-injection fuel delivery system. The PCM will individually monitor both FPDMs through their FPM circuits. The FPDM communicates diagnostic information to the PCM through the FPM circuit. This information is sent by the FPDM as a duty cycle signal. The 3 duty cycle signals that may be sent are listed in the table. Page 6774 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Fuel Tank Pressure Transducer Sensor View 151-15 (Full Body, Left Rear - 1 Of 2) Page 4094 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 Service and Repair Rear Door Panel: Service and Repair REAR DOOR TRIM PANEL Escape Is Shown, Mariner Is Similar Removal and Installation NOTE: LH side is shown. RH side is similar. 1. Remove the rear door trim moulding. 2. Open the cover, remove the screw and the rear door handle bezel. 3. Remove the rear door handle cup screw. 4. Remove the rear door trim panel. A/T - Engine Stall Upon Gear Engagement Torque Converter: Customer Interest A/T - Engine Stall Upon Gear Engagement TSB 07-5-6 03/19/07 CD4E - ENGINE STALLING ON ENGAGEMENT/STOPPING FORD: 2005-2008 Escape MERCURY: 2005-2008 Mariner ISSUE Some 2005-2008 Escape and Mariner vehicles equipped with a CD4E automatic transaxle and built from 8/1/2004 through 2/15/2007 may exhibit an engine stall when coming to a stop or when engaging the transmission into drive or reverse. This condition may be intermittent and often occurs after extended drives. There may be no diagnostic trouble codes (DTCs) stored. This may be caused by internal wear in the torque converter which prevents it from unlocking. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Inspect and repair all non transaxle codes per Workshop Manual (WSM) and Powertrain Controls/Emissions Diagnosis (PC/ED) manuals. 2. Use the Integrated Diagnostic System equipment to monitor the PIDs (Parameter Identification) for TC_SLIPACT as the stall is occurring. a. If the slip is greater than 20 RPM, the stalling is not transaxle related. Repair following PC/ED procedures for engine stalling condition. b. If TC_SLIPACT is less than 20 RPM with the transmission in park or neutral, torque converter internal failure is the most likely cause, proceed to Step 3. 3. Remove the transaxle assembly and check the rotation of the torque converter in the bell housing. A failed converter will be difficult to rotate. 4. Remove the torque converter, drain the automatic transmission fluid (ATF) and refill the CD4E transmission assembly using MERCON(R) V ATF. 5. Install a new torque converter and reinstall the transaxle assembly. 6. Back flush the transmission cooler system as described in the WSM, Section 307-01A. 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 070506A 2005-2008 Escape/Mariner 5.2 Hrs. 4X2 2.3L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, Page 6406 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 1529 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 4206 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. With the vehicle in NEUTRAL, position it on a hoist. 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 bearing must be installed. Page 1860 Brake Fluid: Service and Repair Brake Fluid Reservoir Brake Fluid Reservoir Material Removal and Installation 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. 1. Remove the reservoir cap. 2. Disconnect the brake fluid level warning switch electrical connector. 3. Using a suitable suction device, remove the brake fluid from the brake master cylinder reservoir. 4. If equipped with a manual transmission, disconnect the clutch master cylinder feed hose. Page 4160 2. Remove the rear driveshaft universal joint caps. 1 Index-mark the pinion and pinion flange to the rear of the driveshaft. 2 Remove the 4 bolts and the 2 cap straps. ^ Support the driveshaft. 3. NOTE: Discard the nut after removing it. Install a new nut during installation. Using the special tool, hold the pinion flange while removing the nut. ^ Remove the nut. 4. Index-mark the location of the pinion to the yoke. 5. Using the special tool, remove the pinion flange. Page 7457 J1-J3 Page 2628 Air Flow Meter/Sensor: Diagrams Specifications Brake Drum: Specifications Rear Brake Drum Maximum inside diameter ........................................................................................................................................................ 230.10 mm (9.0590 inch) Page 5476 1. Using the special tools, install a new wheel bearing into the wheel knuckle. 2. Install the wheel bearing snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. FWD vehicles 4. Install the ABS wheel speed sensor ring. 5. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 4WD vehicles 6. Install the wheel knuckle. Page 1585 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 11. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. 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). Page 5795 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Page 6419 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Steering/Suspension - Front End Click/Pop On Bumps Stabilizer Link: Customer Interest Steering/Suspension - Front End Click/Pop On Bumps TSB 09-24-2 12/14/09 CLICK/POP NOISE FROM FRONT STABILIZER BAR END LINK AREA WHEN DRIVING OVER BUMPS - BUILT ON OR BEFORE 10/9/2009 FORD: 2005-2010 Escape MERCURY: 2005-2010 Mariner ISSUE Some 2005-2010 Escape, Escape Hybrid, Mariner and 2006-2010 Mariner Hybrid vehicles built on or before 10/9/2009 may exhibit a click/pop noise from the front end when going over bumps. This may be due to the stabilizer bar end link to strut (upper) attachment. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Using chassis ears, can the click/pop noise be isolated to the stabilizer bar end links? a. No - Do not continue with this procedure. Follow normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes - Proceed to Step 2. 2. Inspect the stabilizer bar end link to strut (upper) attachment nuts for signs of looseness. Is any evidence present of loose upper nuts? a. No - Replace stabilizer bar end links and install revised upper nuts per WSM, Section 204-01. NOTE THE REVISED, TALLER NUTS CANNOT BE INSTALLED ON THE STABILIZER BAR END LINK LOWER ATTACHMENT. b. Yes - Remove and replace both upper nuts with revised, taller nuts per WSM, Section 204-01. Torque to 46 lb-ft (63 N.m). It is not necessary to replace the stabilizer bar end link. 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 092402A 2005-2010 Escape, 1.1 Hrs. Mariner, Escape Hybrid, 2006-2010 Mariner Hybrid: Diagnose With Chassis Ears And Road Test, Inspect Stabilizer Bar End Links, Replace Four (4) Stabilizer End Link Nuts Or Stabilizer Bar End Links (Do Not Use With Any Page 6434 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 7716 Parking Lamp Relay: Testing and Inspection Page 3025 Complete. 7. If the data is not available in the PCM, the WDS displays a screen stating to contact the As-Built Data Center. Retrieve the data from WWW.FMCDEALER.COM at this time and press the check mark. 8. Enter the module data (the module address and line are displayed to the left of the 3 entry boxes) and press the check mark. 9. The WDS downloads the data into the new module and displays Operation Successful - Programming Complete. 10. Test the module for correct operation. Using the Worldwide Diagnostic System (WDS) When the Original Body Chassis Electrical Module is Available 1. Connect the WDS and ID the vehicle as normal. 2. From the Toolbox icon, select and highlight Module Programming and press the check mark. 3. Select and highlight Programmable Module Installation. 4. Follow the on-screen instructions, turn the ignition key to the OFF position, and press the check mark. 5. Install the new module and press the check mark. 6. Follow the on-screen instructions, turn the ignition key to the ON position, and press the check mark. 7. The module configuration is complete. 8. Test the module for correct operation. System Diagnosis P078x Page 4921 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 6418 Page 3610 Throttle Body: Description and Operation Throttle Body Housing THROTTLE BODY HOUSING The throttle body housing assembly is a single piece aluminum or plastic casting with an air passage and a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed) position, the throttle lever arm should be in contact with the throttle return stop. The throttle return stop prevents the throttle plate from contacting the bore and sticking closed. The setting also establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate air flow, a special coating is applied to the throttle plate and bore to help seal this area. This sealant/coating also makes the throttle body resistant to engine intake sludge accumulation. Features of the Throttle Body Assembly include: 1. 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 TP sensor. 7. A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to engine intake sludge accumulation. These throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal advising not to clean. 8. A non-adjustable stop screw for close plate idle air flow. Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Liftgate Ajar Switch View 151-25 (Liftgate) Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 5972 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 6487 Special Tool(s) Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 7751 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH Removal and Installation 1. NOTE: The fog lamp switch is removed by pushing from behind. Remove the fog lamp switch from the instrument panel. Disconnect the fog lamp switch electrical connector. 2. To install, reverse the removal procedure. Page 795 P2112 Page 4635 Page 1260 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 6905 View 151-22 (Left Front Door) Page 5471 Special Tool(s) Removal NOTE: If removing the wheel hub, the wheel bearing must be replaced. 1. Remove the wheel knuckle. 2. Using the special tool, press the wheel hub from the wheel bearing. Heated Seat Module, Driver Side Front View 151-20 (Driver Seat) P0660 P0660 Page 1542 2. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the C-pillar sheet metal. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 4. Install the C-pillar trim panel. 5. Repower the system. Page 2158 Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced. - Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Cam Timing (VCT) System Variable Cam Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system 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 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Page 4158 3. CAUTION: Inspect the inboard CV joint seal journal for rust or nicks/scratches prior to installing the halfshaft. If necessary, polish the seal journal with fine crocus cloth. Install the halfshaft assembly. Page 6978 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. Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Testing and Inspection Micro ISO Relay: Testing and Inspection Page 2911 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Locations View 151-24 (Rear Door (RH Side Shown, LH Side Similar)) Audio System - Front Door Speaker Buzzing Speaker: Customer Interest Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION BASIC PART NO. CODE 78237A05 12 Page 6284 Symptom Chart (Part 4) Communications Network Information Bus: Testing and Inspection Communications Network Principles of Operation PRINCIPLES OF OPERATION The vehicle has 3 module communication networks: high speed and medium speed CAN network, which are comprised of unshielded twisted pair cable, and the international standards organization (ISO) 9141 communication network, which is a single wire network. All 3 networks are connected to the data link connector (DLC). This makes diagnosis and testing of these systems easier by allowing a diagnostic tester to be able to diagnose and control any module on the 3 networks from the connector. The DLC can be found under the instrument panel between the steering column and the radio. The high speed and medium speed CAN remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or voltage. If any of the termination resistors are lost, communication is not possible. The ISO 9141 communication network does not permit intermodule communication. When the diagnostic tool communicates to modules on the ISO 9141 communication network, the diagnostic tool must ask for all information; the modules cannot initiate communications. The ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Also, if one of the modules on the ISO 9141 communication network loses power or shorts internally, communication to that module will fail. Inspection and Verification INSPECTION AND VERIFICATION 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Smart junction box (SJB) fuse 7 (10A) - Wiring harness - Network connections - Data link connector (DLC) C251 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, 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. GO to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck) Pinpoint Test PC (Precheck) PINPOINT TEST PC: DATA LINK DIAGNOSTICS NETWORK TEST Page 1826 Hose/Line HVAC: Service and Repair Suction Accumulator to Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Page 3232 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 6054 10. Unzip the 2 backrest trim cover zippers (one each side). 11. NOTE: - The inboard and outboard head restraint sleeves are not interchangeable. - The head restraint sleeves incorporate an alignment tab that must be aligned correctly when installed. Squeeze together the tip of each head restraint sleeve and pull the 4 sleeves out of the frame tube. 12. 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 and remove the seat backrest trim cover. 13. Remove the backrest foam pad from the backrest frame. 14. Release the seat latch cable from the retractor. 15. Remove the 2 nuts and the safety belt guide. - To install, tighten to 40 Nm (30 lb-ft). 16. Remove the nut and the rear center safety belt retractor. - To install, tighten to 40 Nm (30 lb-ft). 17. To install, reverse the removal procedure. 18. Check the active restraint system for correct operation. - Make sure that after the rear safety belt retractor is installed, the retractor is not in the automatic locking retractor (ALR) mode. Locations Page 1284 Page 7855 Heated Glass Element Relay: Testing and Inspection Page 943 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 877 The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat and depower the SRS. 2. Using a small flat-blade screwdriver, release the locking tab and slide the heated seat module off the bracket. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. 4. Install the front seat and repower the SRS. Page 5737 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: 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 a 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 4132 6. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 7. Move the shifter through all gears from PARK to DRIVE several times making sure that the screw is not too tight. Locations View 151-13 (Behind Dash Panel) Page 5335 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 2676 Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 4226 Drive/Propeller Shaft: Service and Repair Removal and Installation Driveshaft Removal and Installation WARNING: The normal operating temperature of the exhaust system is very high. Never attempt to remove any part of the system until it has cooled. Be especially careful when working around the catalytic converters. The temperature of the converter rises to a high level after only a few minutes of engine operation. Failure to follow these instructions may result in personal injury. CAUTION: Do not swap driveshaft assembles from different vehicles. The Escape Hybrid drive shaft is longer than the driveshaft in the Page 5730 Refrigerant: Service and Repair Contaminated Refrigerant Handling CONTAMINATED REFRIGERANT HANDLING 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 repair facility in your area with the correct equipment to carry out this repair. 2. Determine and correct the cause of the customer's initial concern. 3. Flush the air conditioning system. 4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations. Page 174 P0262 Page 7658 Symbols Part 2 Page 5099 Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and experienced by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering are used to describe the poor return of the steering wheel to center after a turn or steering correction. Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. ^ A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (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). Effort may be said to be flat on-center. ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a driveability problem, it is important to understand the difference between wander and poor groove feel. Page 3605 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 7898 Page 5645 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 5000 Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) 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 ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 5699 11. Remove the A/C compressor manifold and tube assembly. - Remove and discard the O-rings. 12. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 4850 Page 7208 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 7519 B7-B8 Normal Operation When a door or liftgate is opened, the ajar switch opens the circuit to the SJB. The SJB grounds the interior lamp 401 (PK) circuit, illuminating the interior lamps. Possible Causes - circuit 401 (PK) short to ground - circuit 570 (BK/WH) open - circuit 700 (WH/PK) open or short to voltage - circuit 701 (LB/BK) open or short to voltage - circuit 760 (PK/LB) open or short to voltage - circuit 867 (DB) open or short to voltage - circuit 1312 (LG/BK) open or short to voltage - circuit 1742 (VT/LG) open or short to voltage - circuit 1758 (WH/PK) open or short to voltage - ajar switches - SJB Test C: The Interior Lamps Do Not Turn On With One Door Open PINPOINT TEST C: THE INTERIOR LAMPS DO NOT TURN ON WITH ONE DOOR OPEN Page 6412 Page 6889 Page 5540 Page 6913 Page 7541 Daytime Running 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 4779 Starter Motor: Diagrams Page 2688 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 6471 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Diagrams Page 7826 Y4-Y5 Page 1874 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Specifications Exhaust Manifold: Specifications NOTE: Make sure to tighten the nuts in the sequence in 2 stages. Exhaust Manifold nuts Tighten the 7 exhaust manifold nuts in the sequence shown. Stage 1: Tighten to .............................................................................................................................. ........................................... 47 Nm (35 ft. lbs.). Stage 2: Tighten to .................................................... ..................................................................................................................... 47 Nm (35 ft. lbs.). Page 125 P0181 Page 7213 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 6481 Trailer Lamps: Pinpoint Tests Smart Junction Box (SJB) C2280c Trailer Tow C439 Test Y: Trailer Lamps Are Inoperative PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE Page 1178 Page 3077 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 3178 Manifold Pressure/Vacuum Sensor: Diagrams Page 7106 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the outboard front seat side cushion shield. - If removing the outboard passenger seat side cushion shield, remove the 2 screws and slide the shield forward. Disconnect the heated seat switch electrical connector. - If removing the driver seat side cushion shield, remove the 3 screws. Disconnect the heated seat switch electrical connector. - If equipped, disconnect the seat control switch electrical connector. 4. Remove the heated seat switch. 5. To install, reverse the removal procedure. 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) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Page 7502 89-2 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 6823 This program involves lowering the headliner enough to inspect the structural foam blocks which are mounted above the front corners of the headliner. Depending on the results of the inspection, dealers will either release the vehicle, or modify the structural foam blocks using a special tool and a 5/8 inch auger bit. See Figure 1. SERVICE PROCEDURE CAUTION: Failure to perform all disassembly steps as outlined increases the possibility of damaging the headliner. CAUTION: Make sure your hands are clean before performing this repair. NOTE: Although the headliner does not have to be removed to carry out the inspection or modification, a number of trim panels and components must be removed or repositioned in order to lower the front of the headliner for access. Performing all steps as outlined will position the headliner adequately for access to the repair area. NOTE: If the vehicle is equipped with any aftermarket or dealer-installed options, such as a DVD player that interferes with adequately lowering the headliner, they must be removed. DISASSEMBLY FOR INSPECTION NOTE: Perform the following steps on both sides of the vehicle. 1. Open the A-pillar assist handle bolt covers, then remove the bolts and the assist handles. 2. Remove the A-pillar trim panels. 3. At the B-pillars, remove the D-ring covers and the safety belt bolts. 4. Remove the upper B-pillar bolt covers and the bolts, then remove the B-pillar trim panels. 5. If equipped, remove the overhead console retaining screws and disconnect the electrical connector, then remove the console from the vehicle. 6. Remove the sunvisors and sunvisor clips. If equipped, disconnect the electrical connectors. 7. Open the rear seat overhead assist handle bolt covers, then remove the bolts and the assist handles. 8. Position the front and rear door weatherstrips down away from the headliner. 9. Allow the headliner to hang down loosely at the front corners. Do not pull down on the headliner or otherwise stress it, or damage may result. INSPECTION Page 1584 4. Attach the seat cushion trim cover J-clips to the seat cushion pan. 5. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 6. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). 7. Connect the electrical connector(s) and wiring clips. 1 Connect the seat wire harness OCS electrical connector to the service part OCS electrical connector. 2 Install the 2 wiring clips on the wiring harness to the cushion pan. 3 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 4 Tie strap the unused seat wire harness pressure sensor electrical connector safely out of the way. 5 Tie strap all loose wire harnesses and electrical connectors safely out of the way. 8. Install the passenger seat into the vehicle. 9. Repower the system. Do not prove out the system at this time. 10. CAUTION: - 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. Page 6022 4. Use a threaded insert (N807170-S190) provided in D-Ring Installation Kit 100-F012 (134-00018) or equivalent and screw it into the retapped hole until it is slightly below the surface of the hole. 5. NOTE: If the two hex-head bolts on the front seat shoulder strap adjuster are not stripped, refer to Safety Belt Shoulder Height Adjuster to install the height adjuster to the body. If the front seat shoulder strap adjuster bolts are stripped, install a new adjuster. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit 100-F012 (134-00018) several times to drive down the insert keys. Page 227 P0326 P1150 P1150 Page 2506 Radiator: Service and Repair Radiator-2.3L Removal and Installation 1. With vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the cooling fan motor and shroud. 4. Disconnect the upper radiator-to-degas bottle hose from the radiator. 5. Disconnect the upper radiator hose from the radiator. 6. Disconnect the lower degas bottle-to-radiator hose from the radiator. 7. Disconnect the lower radiator hose from the radiator. 8. Disconnect the 2 transaxle cooling hoses from the radiator. 9. Remove the radiator. 10. To install, reverse the removal procedure. 11. Fill and bleed the cooling system. Locations View 151-10 (Automatic Transmission) Page 5186 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Page 457 P1101 Page 5606 Diagrams Wheel Speed Sensor-Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front Wheel Speed Sensor-Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The harness connector is located in the engine compartment. Disconnect the electrical connector. 3. Using a suitable tool, remove the grommet. 4. Remove the front wheel speed sensor wire from the retainer. 5. Remove the 2 front wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). Page 4282 2. NOTE: Both gearshift cables disconnect from the transmission in the same manner. Disconnect the gearshift cables from the transmission. 1 Lift the gearshift cables out of the cable bracket. 2 Disconnect the gearshift cables from the transaxle gearshift control assembly. 3 Remove the 2 gearshift cable clips. 3. Remove the 2 gearshift cable clips. 4. Disconnect the 2 gearshift cables from the gearshift lever. 5. Remove the 2 gearshift cable grommet nuts. 6. Remove the gearshift cables. Installation 1. CAUTION: When inserting the gearshift cables through the dash panel, make sure the arrow on the grommet is pointing down. Insert the gearshift cables through the dash panel. 2. Connect the select cable. Page 532 P1263 Page 5067 P0261 P0261 System Diagnosis P2135 Page 2794 Throttle Position Sensor: Diagrams Page 2111 Wheel Fastener: Service and Repair Rear Removal and Installation 1. Remove the wheel bearing and hub. 2. Using a suitable press, remove the wheel studs from the wheel hub. 3. To install, reverse the removal procedure. Fuel Tank Pressure Transducer Sensor View 151-15 (Full Body, Left Rear - 1 Of 2) Page 2948 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Specifications Firing Order: Specifications Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 186 P0271 Page 6496 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 2407 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes necessary to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. Diagrams System Diagnosis P0840 Page 2117 Parts Block WARRANTY STATUS: Information Only Disclaimer Page 6980 Sunroof / Moonroof: 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. 101-1 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 Locations Cabin Air Filter: Locations CABIN AIR FILTER Removal and Installation 1. Remove the RH cowl panel grille. 2. Remove the 2 water shield screws and the water shield. 3. Remove the cabin air filter. 4. To install, reverse the removal procedure. Vanity Mirror Lamp, Left Page 3552 Fuel Pump Relay: Testing and Inspection Master Window/Door Lock/Unlock Switch ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Page 4196 4. Using the special tool, separate the halfshaft from the rear axle hub assembly. 5. CAUTION: Do not damage the oil seal protector when removing the axle halfshaft from the differential. Using the special tool, remove the halfshaft. Installation 1. CAUTION: Make sure that the oil seal protector is properly aligned with the differential oil seal during installation. Using the special tool, install the halfshaft into the differential. 2. If the axle is equipped with the oil seal protector, make sure the oil seal lip and seal protector are correctly aligned. Description and Operation Navigation System: Description and Operation NAVIGATION SYSTEM The navigation system is integral to the audio unit. The audio unit controls the operation of the navigation system, the audio system and the 6 compact disc (CD) changer. A map CD stored in the audio unit visually guides the user with the maneuvers required to arrive at the destination entered. The 6 CD changer provides audio CD capability while the navigation CD in the audio control unit provides navigation. In order to calculate initial vehicle position, a global positioning system (GPS) antenna is used to track several available satellites simultaneously. The GPS antenna only receives data and does not communicate with the satellites. A hardwired reverse input from the smart junction box (SJB) and a hardwired vehicle speed input from the anti-lock brake system (ABS) module are also used to improve the accuracy of the navigation system. The navigation system also displays separate user selected screens for high voltage power flow and fuel economy. The data is supplied from the controller area network (CAN) and then translated from CAN messages into audio control protocol (ACP) messages by the ACP module. These ACP messages are used by the audio unit to calculate the high voltage power flow and fuel economy screens. Page 4211 Wheel Bearing: Service and Repair Rear Wheel Bearing 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 996 Page 3334 EGR Valve: Service and Repair EXHAUST GAS RECIRCULATION (EGR) VALVE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the air cleaner outlet pipe. 4. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 5. Disconnect the upper radiator hose from the coolant outlet. 6. Disconnect the coolant hose from the EGR valve. 7. Remove the 2 bolts and the EGR valve. - Discard the gasket. - To install, tighten to 25 Nm (18 lb-ft). 8. To install, reverse the removal procedure. - Clean and inspect the EGR gasket mating surfaces. 9. Fill and bleed the cooling system. Page 6326 Amplifier: Service and Repair SUBWOOFER AMPLIFIER Removal and Installation 1. Disconnect the battery. 2. Remove the RH rear quarter trim panel. 3. Disconnect the subwoofer amplifier electrical connector. 4. Remove the 4 screws and the subwoofer amplifier. 5. To install, reverse the removal procedure. Page 1390 Manifold Pressure/Vacuum Sensor: Diagrams Page 5834 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) Fuel System - Fuel Tank Slow to Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Fuel Tank Slow to Fill/Nozzle Shuts Off TSB 05-18-4 09/22/05 SLOW FUEL FILL - REPEAT FILLING STATION PUMP SHUT-OFF FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner ISSUE Some 2005-2006 Escape, Escape Hybrid and Mariner vehicles may exhibit a slow fuel fill or frequent filling station pump shut-offs, when refueling. ACTION Install a revised fuel tank filler pipe. The revised pipe has an improved radius to increase the fuel flow rate. Refer to Workshop Manual Section 310-01A. NOTE THIS CONDITION MAY STILL OCCUR ON SOME VEHICLES EVEN AFTER THE REVISED FUEL TANK FILLER PIPE HAS BEEN INSTALLED. SOME FILLING STATION PUMPS MAY DELIVER FUEL AT A RATE GREATER THAN THE DOT SPECIFICATION, OR MAY USE NOZZLE DESIGNS THAT ARE OVERLY SENSITIVE AND TEND TO SHUT OFF PREMATURELY. THIS IS NORMAL. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051804A 2005-2006 Escape/Mariner: 0.7 Hr. Install A Revised Filler Neck (Do Not Use With 9034A) 051804B 2005-2006 Escape Hybrid: 0.8 Hr. Install A Revised Filler Neck (Do Not Use With 9034A) DEALER CODING CONDITION BASIC PART NO. CODE 9A089 42 Disclaimer Brakes - Rear Disc Brake Grinding/Rubbing/Thumping Brake Rotor/Disc: Customer Interest Brakes - Rear Disc Brake Grinding/Rubbing/Thumping TSB 05-13-8 07/11/05 REAR DISC BRAKE GRIND, RUBBING OR THUMP NOISE FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner This article supersedes TSB 05-9-25 to increase the labor operation time. ISSUE Some 2005 vehicles may exhibit a rear disc brake grind, rubbing or thump. The noise may be more noticeable during cool or wet conditions, and usually occurs during initial brake application after setting over night. This may be due to the composition of the brake lining material. ACTION Machine the rear rotors and install new rear disc brake linings made of revised material. Refer to Section 206-04 of the Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051308A 2005 Escape, Manner, 1.5 Hrs. Escape Hybrid: Machine The Rear Brake Rotors And Install New Rear Disc Brake Linings (Do Not Use With 2001B, 2001B1, 2001B3P, 2001B3PT) DEALER CODING CONDITION BASIC PART NO. CODE 2200 D4 Disclaimer Page 1333 Camshaft Position Sensor: Diagrams Diagrams Page 5838 View 151-19 (Center Console) Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 1848 Disclaimer Page 7470 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. Remove the stoplamp switch. Installation 1. CAUTION: Initial installation of the stoplamp switch allows for one adjustment. If additional adjustments are required, install a new stoplamp switch. Rotate the knob counterclockwise to the stop to unlock. 2. With the engine running, fully apply the brake pedal. 3. Install the stoplamp switch and slowly release the brake pedal. 4. Connect the stoplamp switch electrical connector. Page 6070 Seat Belt Tensioner: Service and Repair Safety Belt Pretensioner Disposal Deployed SAFETY BELT PRETENSIONER DISPOSAL - DEPLOYED 1. WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling a safety belt retractor/pretensioner assembly. This will reduce the risk of injury in the event of an accidental deployment. 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 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. Depower the system. 2. Remove the inoperative safety belt buckle pretensioner or safety belt retractor pretensioner from the vehicle. 3. 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: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module or safety belt retractor/pretensioner assembly. This will reduce the risk of injury in the event of an accidental deployment. - 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 assembly 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 air bag is deployed, hearing protection is required. - Do not position the safety belt retractor/pretensioner assembly so that moveable parts contact the support surface, as the forces of the deploying pretensioner can cause it to ricochet and cause personal injury. NOTE: A typical safety belt buckle/retractor pretensioner is shown that is similar for all vehicles. All pretensioners 1. Depower the system. 2. Remove the safety belt pretensioner from the vehicle. Safety belt buckle pretensioner Page 5360 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 6993 2 While sliding the track studs through the seat track motor assembly, position the pinion cage opening around the seat track motor assembly gear. 3 Fit the support straps and seat track motor assembly gear bushing alignment pins into the track openings. 7. When assembled, make sure the outboard track, support straps, front and rear height adjustment gears and seat track motor assembly all fit flush against each other. Make sure the support straps and seat track motor assembly gear bushing alignment pins fit into the track openings. 8. CAUTION: Do not overtighten or damage will occur. Install the two bolts holding the seat track motor assembly to the outboard track. 9. Install the two nuts. 10. Install the outboard retainer clip. Diagrams Clutch Pedal Assembly: Diagrams Page 1012 ^ 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 Torque Specifications Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 3186 Oxygen Sensor: Harness Locations View 151-8 (Engine, rear) P0505 P0505 Page 4088 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Specifications Axle Nut: Specifications Wheel hub nut Tighten to ............................................................................................................................................. ........................................... 290 Nm (214 ft. lbs.) P1705 P1705 Page 800 P2122 System Diagnosis P0430 Page 3341 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Description and Operation Seat Belt Reminder Lamp: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: 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 4 to 8 seconds with no chime. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver's 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 Seat Belt Systems. Forward Crash Sensor View 151-3 (Engine Compartment, 1 Of 2) Page 6066 Seat Belt Tensioner: Description and Operation Supplemental Restraint System Safety Belt Buckle Pretensioners - All Vehicles As part of the SRS, the safety belt buckles are equipped with pretensioners. The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are activated by the restraints control module (RCM) when the module detects a impact event force exceeding a programmed limit. Safety Belt Retractor Pretensioner - Escape Hybrid Only As part of the SRS, the driver safety belt retractor for the Escape Hybrid is equipped with a pretensioner. The pretensioner removes excess slack from the safety belt webbing. The pretensioner is activated by the RCM when the module detects an impact event force exceeding a programmed limit. Page 6937 Interior Trim Interior trim codes are listed as a two-part code. The first character identifies the interior trim type. The second character identifies the interior trim color. Interior Trim Type 5 - Nudo leather seats - A - Captains cloth seats - B - No Boundaries cloth seats - B - Impulse cloth seats - C - Imola leather seats - N - Toscana leather seats - W - XLS cloth seats Interior Trim Color 2 - Medium Dark Flint - B - Ebony - T - Dark Flint Tape/Paint Stripe Page 4480 Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Diagrams Page 1075 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 7612 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. P1275 P1275 Page 948 Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Page 2280 ^ To install, tighten in the sequence shown to 25 Nm (18 ft. lbs.). 6. Install the oil level indicator and tube. 7. Fill the engine with clean engine oil. Page 6738 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Page 7894 Page 4431 Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 46 P0109 Page 5882 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar SIDE IMPACT SENSOR - SECOND ROW, C-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the C-pillar trim panel. 3. Remove the side impact sensor bolt. 4. Disconnect the electrical connector and remove the side impact sensor. Installation 1. Connect the electrical connector to the side impact sensor. Page 1829 Condenser Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Remove the RH splash shield. 5. If equipped, disconnect the block heater electrical connector. 6. Remove the compressor to condenser discharge line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the compressor to condenser discharge line from the compressor. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the condenser core peanut fitting nut and disconnect the condenser core peanut fitting compressor. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor to condenser discharge line. 10. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Page 5811 Air Bag: Diagrams Side Air Curtain Module Page 2994 Information Bus: Description and Operation COMMUNICATIONS NETWORK Smart Junction Box (SJB) The SJB is connected to the medium speed controller area network (CAN) communications bus. If one of the bus wires becomes shorted to ground or voltage, communications can continue at a reduced level. Check circuits 1847 (WH/OG), and 1848 (PK/OG) between the SJB C2280a, the instrument cluster C220 and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the medium speed CAN, damage to the DLC C251, or damage to the SJB C2280a. Since both the SJB and the instrument cluster share network termination responsibilities, a problem in either of these modules can result in a medium speed CAN failure. Powertrain Control Module (PCM) The PCM is on the high speed CAN. The PCM controls the engine for better fuel economy, emissions control, failure mode detection and storage, and all passive anti-theft system (PATS) functions. If one of the bus wires becomes shorted to ground or voltage, communications can continue at a reduced level. Check the high speed CAN circuits 1908 (WH) and 1909 (BK), between the PCM C175b and the DLC C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the high speed CAN, damage to the DLC C251, damage to the PCM C175b, or a problem in the in-line connector. Since both the PCM and the instrument cluster share network termination responsibilities, a problem in either of these modules can result in a high speed CAN failure. Instrument Cluster The instrument cluster is on the high speed CAN. It is an analog face cluster with a digital odometer. The instrument cluster displays a variety of information. If one of the bus wires becomes shorted to ground or voltage, communications can continue at a reduced level. Check the high speed CAN circuits 1908 (WH) and 1909 (BK) between the instrument cluster C220 and the DLC C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the CAN network, damage to the DLC C251, damage to the instrument cluster C220, or a problem in the in-line connector. Since both the PCM and the instrument cluster share network termination responsibilities, a problem in either of these modules can result in a high speed CAN failure. Restraint Control Module (RCM) The RCM is on the international standards organization (ISO) 9141 communication network. The RCM controls the deployment of the air bags based on sensor input. The ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Check the network circuit between the RCM C2041a and the DLC C251. Total resistance value must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the ISO 9141 communication network, damage to the DLC C251, damage to the RCM C2041a, or a problem in the in-line connector. Anti-Lock Brake System (ABS) Module The ABS module is on the high speed CAN. The ABS module controls the brake pressure to the 4 wheels to keep the vehicle under control while braking. If one of the bus wires becomes shorted to ground or voltage, communications can continue at a reduced level. Check the high speed CAN circuits 1908 (WH) and 1909 (BK), between the ABS module C155 and the DLC C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the high speed CAN, damage to the DLC C251, damage to the ABS module C155, or a problem in the in-line connector. Parking Aid Module The parking aid module is connected to the ISO 9141 communication network. The parking aid module receives input from sensors in the rear bumper that detect close objects when the transmission is in REVERSE, and the vehicle speed is above 0 km/h (0 mph) and below 8 km/h (5 mph). The ISO 9141 communication network will not function if the wire is shorted to ground or battery voltage. Check the network circuit between the parking aid module C4014 and the DLC C251. Total resistance value must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the ISO 9141 communication network, damage to the DLC C251, damage to the parking aid module connector, or a problem in the in-line connector. Four-Wheel Drive (4WD) Control Module The 4WD control module is on the high speed CAN. The 4WD control module regulates the duty cycle to the active torque coupling between FWD and 4WD when more traction is required. Check the high speed CAN circuits 1908 (WH) and 1909 (BK), between the 4WD control module C3253 and the DLC C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open circuit in the high speed CAN, damage to the DLC C251, damage to the 4WD control module C3253, or a problem in the in-line connector. Page 6528 Escape Is Shown, Mariner Is Similar (Part 2) Removal and Installation CAUTION: Prior to removal of the front bumper cover, place tape at the corners of the bumper cover and below the headlamps to prevent damage to the paint. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 6 pin-type retainers (3 each side). 3. Remove the 4 fender splash shield bolts (2 each side). - To install, tighten to 8 Nm (71 lb-in). 4. Remove the 4 air deflector bolts. - To install, tighten to 8 Nm (71 lb-in). 5. Remove the 2 center front bumper cover pin-type retainers. 6. Remove the 2 front bumper cover outer pin-type retainers (1 each side). 7. If equipped, disconnect the fog lamp electrical connectors. 8. Remove the 2 upper bolts and the front bumper cover. - To install, tighten to 8 Nm (71 lb-in). 9. To install, reverse the removal procedure. - Position the front bumper cover. - Push inward on the sides of the bumper cover near the bottom corner of the headlamp until you feel the bumper cover snap onto the bumper slides. Page 4097 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 7849 Page 5295 - To install, tighten to 200 Nm (148 lb-ft). 21. Support the front subframe and remove the 2 front subframe nuts. - To install, tighten to 150 Nm (111 lb-ft). All vehicles 22. NOTE: The lower control arm ball joints must be disconnected from the spindles at the same time the subframe is lowered. With an assistant, remove the front subframe. 23. To install, reverse the removal procedure. Specifications Axle Nut: Specifications Wheel hub nut Tighten to ............................................................................................................................................. ........................................... 290 Nm (214 ft. lbs.) Page 4545 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove the 2 brake caliper anchor plate bolts. ^ To install, tighten to 150 Nm (111 ft. lbs.). 3. Remove the brake caliper anchor plate. 4. To install, reverse the removal procedure. Page 6737 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 4960 Page 1675 System Diagnosis P1465 - P1469: Testing and Inspection P1469 (Part 1) P1469 (Part 2) Specifications Oil Filter Adapter: Specifications Oil filter adapter bolts ........................................................................................................................... .................................................... 25 Nm (18 ft. lbs.) Page 5122 Using the special tool, separate the tie-rod from the wheel knuckle. 6. Remove the lower ball joint pinch bolt nut and the pinch bolt. 7. Remove the anti-lock brake system (ABS) wheel speed sensor bolt and position the sensor aside. 8. Separate the lower ball joint from the wheel knuckle. 9. Remove the 2 strut-to-knuckle nuts, bolts and the wheel knuckle. Installation 1. Position the wheel knuckle and install the 2 strut-to-knuckle bolts and nuts. ^ Tighten to 115 Nm (85 ft. lbs.). 2. Position and align the ball joint stud into the wheel knuckle. 3. Install the lower ball joint pinch bolt and nut. ^ Tighten to 70 Nm (52 ft. lbs.). 4. Install the ABS wheel speed sensor and the bolt. ^ Tighten to 9 Nm (80 inch lbs.). 5. Position the tie rod-end into the wheel knuckle and install the tie-rod end-to-knuckle nut and a new cotter pin. ^ Tighten to 55 Nm (41 ft. lbs.). 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 8. Install the brake disc. 9. Check and, if necessary, align the front end. Page 4322 Initial Inspection and Diagnostic Overview Accelerator Pedal: Initial Inspection and Diagnostic Overview INSPECTION AND VERIFICATION Verify the condition by operating the accelerator pedal and shaft from idle to wide open-throttle and back again. Check for any resistance in forward travel of the accelerator pedal and shaft or hesitation on return. If a concern exists, visually inspect all components of the accelerator pedal and shaft. Look for damage or binding of the accelerator cable. Look for obstructions at the throttle body and accelerator pedal and shaft. For vehicles equipped with speed control, examine the speed control cable. Testing and Inspection Fan Shroud: Testing and Inspection Cooling Fan Motor and Shroud 1. Inspect the fan blade and shroud for any foreign materials. Clear the obstruction and continue the test procedure. 2. Rotate the fan to see if any contact between the shroud and blade exists. If contact is observed, install a new fan shroud assembly. 3. Rotate the fan by hand. The fan should rotate freely (no resistance should be felt, the fan will free-wheel with minimum effort). If any resistance is present, install a new fan assembly. Page 1827 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the RH splash shield. 4. If equipped, disconnect the engine block heater electrical connector. 5. Disconnect the A/C compressor electrical connector. 6. Remove the suction accumulator to compressor line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the suction accumulator to compressor line from the A/C compressor. 8. Remove the 2 suction accumulator to compressor line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the suction accumulator to compressor line spring lock coupling. 10. Remove the suction accumulator to compressor line. 11. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Compressor to Condenser Discharge Line COMPRESSOR TO CONDENSER DISCHARGE LINE Page 1363 Mechanical Returnless Fuel Pump Module (FPM) Page 6749 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 4884 Selector Lever Shifter CVT: Service and Repair Selector Lever Transmission Selector Lever Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. Page 4039 3. Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and spring ends that are higher or lower than the rest. 4. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury. CAUTION: Loosen the bolts evenly to prevent pressure plate damage. Remove the bolts, clutch pressure plate and clutch disc. 5. CAUTION: Do not use cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent. Using a suitable commercial alcohol based solvent, clean the clutch pressure plate. 6. Inspect the clutch pressure plate surface for burn marks, scores, flatness or ridges. 7. CAUTION: If the clutch disc is saturated with oil, inspect the rear engine crankshaft seal for leakage. If leakage is found, install a new seal prior to clutch disc installation. NOTE: Use an emery cloth to remove minor imperfections in the clutch disc lining surface. NOTE: Install a new clutch disc if any of the following conditions are present. Inspect the clutch disc for: ^ oil or grease saturation ^ worn or loose facings ^ warpage or loose rivets at the hub ^ wear or rust on the splines 8. Check the clutch disc runout and wear. Installation 1. Using the special tool, position the clutch disc on the flywheel. Service and Repair Resonator: Service and Repair INTAKE AIR RESONATOR Page 1011 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 3655 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Page 270 P0406 Page 5797 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Page 7371 Locations Page 1385 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Page 1445 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Liftgate Ajar Switch Page 6052 Seat Belt Retractor: Service and Repair Rear Center Safety Belt Retractor REAR CENTER SAFETY BELT RETRACTOR Removal and Installation WARNING: All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support Testing and Inspection Condenser HVAC: Testing and Inspection A/C EVAPORATOR/CONDENSER CORE - ON VEHICLE LEAK TEST 1. Recover the refrigerant. 2. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the A/C Fittings Set to the evaporator or condenser 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 activates 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 gauge set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C 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 A/C evaporator core or A/C 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 the gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then check for a loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for a vacuum loss. 9. If the A/C evaporator core or A/C condenser core leaks, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Page 1503 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 3674 Ignition Coil: Service and Repair IGNITION COIL-ON-PLUG Exploded View Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connectors. 3. Remove the bolts and the ignition coils. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. - Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Page 2359 2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant. Apply a 2.5-mm (0.09 inch) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5-mm (0.09 inch) bead of silicone casket and sealant to the front cover. 3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications: ^ Tighten the 8-mm bolts to 10 Nm (89 inch lbs.). ^ Tighten the 13-mm bolts to 48 Nm (35 ft. lbs.). Page 6787 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Seat Belt Tensioner, Passenger Seat Page 6837 4. Push the headliner back into its proper position. Clamp in place using a flat piece of metal or wood to keep the headliner flush against the underside of the roof panel (Figure 3). Allow the adhesive to cure for 45 minutes. 5. Remove clamps and reinstall the perimeter seal. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050803A 2004-2005 Escape/Escape 0.3 Hr. Hybrid/Mariner Adhere The Headliner To The Underside Of The Roof Panel (Do Not Use With 51916A, 51916B, 51916BXH) DEALER CODING CONDITION BASIC PART NO. CODE 7851944 34 Disclaimer Driver Side Drivetrain - Fluid leak From PTU Vent Case: Customer Interest Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s) Special Tool(s) Fluorescent Dye Detection NOTE: Vehicles are manufactured 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 1 leak can exist, make sure to inspect each component, line, and fitting in the refrigerant system for a leak. Page 5611 Control Assembly: Service and Repair Function Selector Switch FUNCTION SELECTOR SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the function selector switch knob. 3. Press the tabs simultaneously and remove the function selector switch. 4. To install, reverse the removal procedure. Locations Transmission Pressure Test Port: Locations Specifications Brake Caliper: Specifications Brake caliper anchor plate ................................................................................................................... ................................................. 150 Nm (111 ft. lbs.) Brake caliper guide bolts (disc-drum system) ........................................................................................................................................... 35 Nm (26 ft. lbs.) Brake caliper guide bolts (4-wheel disc brake system) ............................................................................................................................. 45 Nm (33 ft. lbs.) Brake caliper jounce hose (at caliper) ...................................................................................................................................................... 20 Nm (15 ft. lbs.) Page 4872 Locations View 151-13 (Behind Dash Panel) Page 6464 Symbols Part 3 Page 2719 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 5978 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ .............................................................. 907 g (2 lb.) Page 5049 Page 4092 Symbols Part 5 Locations View 151-7 (Engine, front) Right/Left Front View 151-3 (Engine Compartment, 1 Of 2) Page 180 P0267 Page 7824 Y1-Y2 Page 3939 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Remove the shift cable from the gearshift assembly. 1 Disconnect the shift cable end from the gearshift lever. 2 Remove the shift cable from the bracket. Page 4680 7. Remove the brake booster pushrod pin redundant clip. 8. Remove the brake booster pushrod self-locking pin. 9. Remove the brake booster pushrod outer bushing 10. Slide the brake booster pushrod off of the brake pedal pin and position the pushrod aside. 11. Remove the 4 nuts and the brake booster. ^ To install, tighten to 23 Nm (17 ft. lbs.). 12. To install, reverse the removal procedure. Page 1924 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 7669 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 5367 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 2651 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Smart Junction Box Fuse Block: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 1102 Page 1177 Page 2545 4. NOTE: If installing a new converter, remove the heated oxygen sensor (HO2S) and the catalyst monitoring sensor for installation in the new converter. Disconnect the HO2S and the catalyst monitoring sensor electrical connectors. 5. Remove and discard the 7 exhaust manifold nuts. 6. Remove the catalytic converter from the vehicle. ^ Discard the exhaust manifold gasket. Installation 1. CAUTION: If the warpage is greater than 0.76 mm (0.03 inch) replace the catalytic converter. Inspect the catalytic converter for warpage across the manifold flange area. 2. Position a new exhaust manifold gasket on the engine. 3. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak. CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak. NOTE: Make sure to tighten the nuts in the sequence in 2 stages. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown. ^ Stage 1: Tighten to 47 Nm (35 ft. lbs.). ^ Stage 2: Tighten to 47 Nm (35 ft. lbs.). 4. NOTE: Apply anti-seize lubricant to the threads of the sensors before installation. Page 5216 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 Locations View 151-3 (Engine Compartment, 1 Of 2) Page 4532 Brake Bleeding: Service and Repair Manual Bleed Manual Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, to the RH front wheel, and ending with the LH front wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until the fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 8. Continue bleeding the brake hydraulic system at each wheel. 9. Fill the brake master cylinder reservoir with the specified brake fluid. Page 3144 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 7764 Headlamp Switch: Testing and Inspection Page 3538 Exploded View Removal and Installation All vehicles 1. Disconnect the crankcase vent tube from the air cleaner outlet pipe. Vehicles with automatic transaxle 2. Disconnect the vacuum tube from the air cleaner outlet pipe. All vehicles 3. Disconnect the mass air flow (MAF) sensor electrical connector. 4. Loosen the 2 clamps and remove the air cleaner outlet pipe. - To install, tighten to 3 Nm (27 lb-in). 5. NOTE: The air cleaner outlet pipe should be securely sealed to prevent unmetered air from entering the engine. To install, reverse the removal procedure. Page 3527 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE (APPLICATIONS WITHOUT ETC) The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. NOTE: The IAC valve assembly is NOT ADJUSTABLE and CANNOT BE CLEANED, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The PCM uses the IAC valve assembly to control: - No touch start. - Cold engine fast idle for rapid warm-up. - Idle (corrects for engine load). - Stumble or stalling on deceleration (provides a dashpot function). - Over-temperature idle boost. Driver Side Page 2835 Exploded View Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the air cleaner intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Page 3230 Page 3476 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. - The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. If these precautions are not followed, fuel may spray and cause personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Release the fuel system pressure. 3. Disconnect the battery ground cable. 4. Remove the 2 fuel filler pipe mounting screws. 5. Remove the rivets and the fuel tank tube shield. 6. Remove the remaining fuel filler pipe mounting screw. 7. 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. Using the special tool, disconnect the fuel vapor control tube assembly valve quick connect coupling from the fuel tank filler tube. 8. Detach the fuel vapor vent hose retainer clips. 9. Disconnect the fuel vapor vent hose from the evaporative emissions canister. 10. Reposition the clamp and disconnect the fuel filler pipe hose from the fuel tank. - Remove the fuel tank filler pipe as a complete assembly. Installation ABS/TCS - Wheel Speed Sensor Removal Tips Wheel Speed Sensor: Technical Service Bulletins ABS/TCS - Wheel Speed Sensor Removal Tips TSB 04-23-2 11/29/04 WHEEL SPEED SENSOR REMOVAL TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE When servicing the wheel speed sensors on a 2001-2005 Escape or 2005 Mariner and Escape Hybrid, care must be taken during removal to prevent damage. The wheel speed sensor wire has a body plug attached to it. This plug can be damaged if not removed correctly, such as removal for pinpoint testing. If the body plug is damaged, sensor replacement may be necessary even though the sensor is functional in all other respects. ACTION When removing the body plug, rotate the plug into a position which allows the use of a small screwdriver to release the tabs on the underside of the body plug. These two tabs are at right angles (directly above and below) to the sensor wire. See Figures 1 and 2 for reference. WARRANTY STATUS: Information Only Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 486 P1138 Page 3978 2. Disconnect the transmission fluid cooler tube clamps and disconnect the rubber hoses from the auxiliary cooler. 3. Disconnect the upper fluid cooler rubber hose from the radiator. 4. Disconnect the lower fluid cooler rubber hose from the radiator. 5. Disconnect and remove the front cooler tube from the transaxle case. ^ To install, tighten to 25 Nm (18 ft. lbs.). 6. Disconnect and remove the rear cooler tube from the transaxle case. ^ To install, tighten to 25 Nm (18 ft. lbs.). Page 3712 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Page 4928 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 5029 Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Smart Junction Box Fuse: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 2325 1. NOTE: Remove the through-bolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil. Using the special tool, install the crankshaft front oil seal. 2. Install the crankshaft pulley. Page 7293 Symptom Chart (Part 3) Page 2923 Electronic Throttle Monitor Operation (Part 1) Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Fuel Injector 1 Page 6612 Rear Door Latch: Service and Repair Rear Door Latch REAR DOOR LATCH Removal and Installation 1. Remove the interior door handle. 2. Position the rear door glass top run aside. 1 Remove the 2 bolts. To install, tighten to 8 Nm (71 lb-in). 2 Position the rear door glass top run aside. 3. Disconnect the rear door latch electrical connector. 1 Release the clip. 2 Disconnect the electrical connector. 4. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. 5. Remove and discard the 3 rear door latch bolts. - To install, tighten to 8 Nm (71 lb-in). 6. Remove the rear door latch from inside the door frame. 7. To install, reverse the removal procedure. Page 7738 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. Remove the stoplamp switch. Installation 1. CAUTION: Initial installation of the stoplamp switch allows for one adjustment. If additional adjustments are required, install a new stoplamp switch. Rotate the knob counterclockwise to the stop to unlock. 2. With the engine running, fully apply the brake pedal. 3. Install the stoplamp switch and slowly release the brake pedal. 4. Connect the stoplamp switch electrical connector. Page 1244 Dimmer Switch: Testing and Inspection Locations View 151-10 (Automatic Transmission) Locations Page 4755 Alternator: Application and ID ITEM..................................................................................................................................................... ...................................................SPECIFICATION Generator Rating..............................................................................................75/120 amp (max) @ 1,800-6,000 generator rpm, approximately 500-2,000 engine rpm Generator pulley ratio................... .............................................................................................................................................................. ....................2.40:1 Voltage regulator type........................................................................................... ...............................................................Electronic internal with generator Page 7642 A3-A5 Page 598 P1408 Forward Crash Sensor View 151-3 (Engine Compartment, 1 Of 2) Diagrams Page 3930 6. Remove the set screw. 7. Remove the knob and wiring by pulling straight Up on the knob. 8. Remove and discard the shifter straw by pulling it straight up. Installation Page 7563 View 151-25 (Liftgate) Page 5040 Relay Box: Locations Battery Junction Box Page 2860 2. If compression does not improve, valves are sticking or not seating correctly. 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. Liftgate Ajar Switch Page 7980 Wiper Switch: Testing and Inspection Page 4644 Brake Master Cylinder: Testing and Inspection Brake Master Cylinder-Non-Pressure External Leaks Brake Master Cylinder-Non-Pressure External Leaks A low brake fluid level in the brake master cylinder reservoir may be caused by the following non-pressure external leaks: Type 1: An external leak may exist at the brake master cylinder filler cap due to incorrect position of the cap, cap gasket, or cap gasket deterioration. Repair or install new components as necessary. Type 2: An external leak may exist at the brake master cylinder mounting flange due to internal seal failure. Repair or install a new brake master cylinder. Type 3: An external leak may exist at the base of the brake master cylinder reservoir due to deteriorated reservoir mounting seals. Repair or install a new brake master cylinder. Page 5610 5. To install, reverse the removal procedure. - Place the temperature selector switch in the full cold position before installation. Page 2883 7. Remove the SJB screw. 8. Disconnect the electrical connectors and remove the SJB. 9. To install, reverse the removal procedure. - Configure the SJB. Refer to Information Bus (Module Communications Network). Automatic Transaxle Fluid - Transfer Case: Service and Repair Automatic Transaxle Transfer Case Draining and Filling-Automatic Transaxle Material CAUTION: New transfer case lubricant must be installed any time the transfer case has been submerged in water. NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected or a repair is necessary. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the drain plug and drain the transfer case. 3. Apply silicone sealant to the drain plug threads and install the drain plug. ^ Tighten to 10 Nm (89 inch lbs.). 4. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground. Remove the fill plug and fill the transfer case with rear axle lubricant. 5. Apply silicone sealant to the fill plug and install the plug. ^ Tighten to 16 Nm (12 ft. lbs.). Page 2129 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 the 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 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Connector Views Engine Control Module: Connector Views SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: Customer Interest SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Liftgate Ajar Switch View 151-25 (Liftgate) Locations View 151-7 (Engine, front) Page 2747 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Page 4668 Parking Brake Shoe: Service and Repair Parking Brake Shoes Material Material Removal and Installation 1. Remove the rear brake disc. 2. Remove the parking brake shoe upper return spring. 3. Remove the 2 parking brake shoe retaining pins. 4. Remove the 2 parking brake shoe retaining springs. 5. Remove the parking brake shoe lower return spring. 6. Remove the parking brake shoe adjuster. 7. Remove the parking brake shoes. 8. To install, reverse the removal procedure. ^ Using anti-seize lubricant, lubricate the parking brake shoe contact points before installation of the rear parking brake shoes. ^ Lubricate the adjust screw threads with anti-seize lubricant. ^ Adjust the parking brake shoe and lining. ^ Check the parking brake for normal operation. Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault 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, 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 (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block will display on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays 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). Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other enhanced diagnostic tools that may have programming capabilities available. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and 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 is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic 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 installed. Manual data entry must be Carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the WDS or New Generation Star (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Heated Seat Module, Passenger Side Front Page 1121 View 151-22 (Left Front Door) Page 5830 Page 6345 Page 5564 4. Remove the A/C clutch pulley snap ring. 5. Remove the A/C clutch pulley. 6. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Using the special tools, remove the A/C clutch field coil. Installation 1. Clean the A/C clutch field coil and pulley mounting surfaces. 2. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. NOTE: Position the A/C clutch field coil on the A/C compressor as previously marked. Page 4950 Page 927 Power Distribution Relay: Testing and Inspection Page 3316 Leak Detection Valve: Service and Repair EVAPORATIVE EMISSION CANISTER VENT SOLENOID Removal and Installation 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 ground cable. 3. Remove the evaporative emission (EVAP) canister assembly. 4. Disconnect the fuel vapor hose from the EVAP canister vent solenoid. 5. Release the evaporative emission canister vent solenoid from the evaporative hydrocarbon filter. Page 1936 Disconnect the high-pressure and low-pressure valves and remove the injector loop kit from the vehicle. Page 1609 Page 4242 Flexplate, Flywheel and Crankshaft Rear Oil Seal Master Window/Door Lock/Unlock Switch Power Window Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 1074 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 7844 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Diagram Information and Instructions Audible Warning Device: 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 5752 Page 7440 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 4780 Starter Motor: Service and Repair STARTER MOTOR Removal and Installation WARNING: When performing maintenance on the starting system, be aware that heavy gauge leads are connected directly to the battery. Make sure 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 starter motor solenoid terminal cover. 4. Remove the starter solenoid wire nut and position aside the wire. - To install, tighten to 5 Nm (44 lb-in). 5. Remove the starter solenoid battery cable nut and position aside the cable. Brakes - Rear Disc Brake Grinding/Rubbing/Thumping Brake Pad: Customer Interest Brakes - Rear Disc Brake Grinding/Rubbing/Thumping TSB 05-13-8 07/11/05 REAR DISC BRAKE GRIND, RUBBING OR THUMP NOISE FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner This article supersedes TSB 05-9-25 to increase the labor operation time. ISSUE Some 2005 vehicles may exhibit a rear disc brake grind, rubbing or thump. The noise may be more noticeable during cool or wet conditions, and usually occurs during initial brake application after setting over night. This may be due to the composition of the brake lining material. ACTION Machine the rear rotors and install new rear disc brake linings made of revised material. Refer to Section 206-04 of the Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051308A 2005 Escape, Manner, 1.5 Hrs. Escape Hybrid: Machine The Rear Brake Rotors And Install New Rear Disc Brake Linings (Do Not Use With 2001B, 2001B1, 2001B3P, 2001B3PT) DEALER CODING CONDITION BASIC PART NO. CODE 2200 D4 Disclaimer Page 6402 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 4096 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 1022 5. NOTE: The RCM has been removed for clarity. Connect the large RCM electrical wiring 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. 6. Position back the carpet on the LH and RH tunnel to its original position. 7. Install the lower LH center instrument panel finish panel. 8. Repower the system. Page 21 P0041 Page 1884 3. NOTE: Some vehicles are equipped with a cold weather bypass valve which cannot by cleaned or flushed. A new valve should be installed as part of an overhaul or prior to the installation of a remanufactured transaxle. Using compressed air, blow through the coolers until all fluid is removed. Page 4892 Locations Service Port HVAC: Locations Clutch Cycling Orifice Tube Type Refrigerant System (Part 1) P0325 P0325 Page 2630 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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 6976 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. Locations View 151-10 (Automatic Transmission) Page 8018 Wiper Blade: Adjustments Rear Window Wiper Blade and Pivot Arm Adjustment REAR WINDOW WIPER BLADE AND PIVOT ARM ADJUSTMENT 1. Cycle and park the rear window wiper. 2. Verify that the rear window wiper blade is located at the specified position. 3. If not within specification, remove the rear window wiper pivot arm and reposition it to the correct location. Page 7337 Instrument Panel Bulb: Service and Repair Warning Indicator Bulb WARNING INDICATOR BULB Removal and Installation 1. Remove the instrument cluster. 2. NOTE: To remove the warning indicator bulbs, rotate the bulb 1/4 turn counterclockwise and lift it straight out from the instrument cluster. Remove the warning indicator bulb(s) in question. 3. To install, reverse the removal procedure. Page 5861 1. WARNING: Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury. CAUTION: Make sure the road wheels are in the straight-ahead position. If the 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 clockwise, 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 counterclockwise until the yellow indicator shows anywhere in the window (window will be near the 1 o'clock position) and the arrow on the rotor lines up with the arrow on the top of the housing. The clockspring is now centered. Do not allow the rotor to turn from this position. All vehicles 2. Connect the 2 clockspring electrical connectors to the clockspring. Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Locations View 151-8 (Engine, rear) Page 7297 Message Center INFO Switch C253a Message Center SET Switch C253b Test A: The Message Center Does Not Operate Correctly PINPOINT TEST A: THE MESSAGE CENTER DOES NOT OPERATE CORRECTLY Locations View 151-12 (Dash Panel) Page 5859 Clockspring Assembly / Spiral Cable: Service and Repair CLOCKSPRING 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. Page 6821 OASIS ACTIVATED? Yes. OASIS was activated April 5, 2006. FSA VIN LIST ACTIVATED? Yes. FSA VIN lists will be available through the website by May 15, 2006. Owner names and addresses will be available by May 26, 2006. 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 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. If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ 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 the Special Service Support Center. ^ "MT" labor must be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from the Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Page 1951 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: 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 a 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. P0600 P0600 Safety Belt Cleaning Seat Belt: Service and Repair 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. Page 1594 Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault 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, 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 (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block will display on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays 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). Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other enhanced diagnostic tools that may have programming capabilities available. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and 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 is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic 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 installed. Manual data entry must be Carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the WDS or New Generation Star (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Page 7829 Special Tool(s) Page 5548 Blower Motor Resistor: Service and Repair BLOWER MOTOR RESISTOR Removal and Installation 1. Remove the RH A-pillar lower trim panel. 2. Disconnect the blower resistor electrical connector. 3. Remove the 2 screws and the blower motor resistor. 4. To install, reverse the removal procedure. Throttle Body System Overview Throttle Body: Description and Operation Throttle Body System Overview THROTTLE BODY SYSTEM OVERVIEW NOTE: This overview is for applications without electronic throttle control (ETC). For ETC applications, refer to Torque Based Electronic Throttle Control (ETC). The throttle body system meters air to the engine during idle, part throttle, and wide open throttle (WOT) conditions. The throttle body system consists of an idle air control (IAC) valve assembly, an idle air orifice, single or dual bores with butterfly valve throttle plates, and a throttle position (TP) sensor. One other source of idle air flow is the positive crankcase ventilation (PCV) system. The combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor on all applications. During idle, the throttle body assembly provides a set amount of air flow to the engine through the idle air passage and the PCV valve. The IAC valve assembly provides additional air when commanded by the PCM to maintain the proper engine idle speed under varying conditions. The IAC valve assembly mounts directly to the intake manifold assembly in most applications. Idle speed is controlled by the PCM and cannot be adjusted. NOTE: The traditional idle air adjust procedure and the throttle return screw are no longer used on OBD applications. Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle plate. The TP sensor monitors the throttle position and provides a signal to the PCM. Some throttle body applications provide an air supply channel upstream of the throttle plate to provide fresh air to the PCV or IAC systems. Other throttle body applications provide individual vacuum taps downstream of the throttle plate for PCV return, exhaust gas recirculation (EGR), evaporative emission (EVAP), and miscellaneous control signals. THROTTLE BODY SYSTEM HARDWARE The major components of the throttle body assembly include the TP sensor, the IAC valve assembly, and the throttle body housing assembly. Page 7778 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 7014 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 Exhaust Resonator: Service and Repair Resonator Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 resonator nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 3. Remove and discard the resonator exhaust hanger and remove the resonator. 4. To install, reverse the removal procedure. ^ Install a new resonator gasket. Page 4387 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............. SAE 80W-90 Premium Rear Axle Lubricant Locations View 151-8 (Engine, rear) Page 3174 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 1463 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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. Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Connect the battery. 6. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 10. Support the front door window glass in the full up position. 11. Disconnect the front door window motor electrical connector. 12. Remove the 3 front door window regulator and motor bolts. - To install, tighten to 6 Nm (53 lb-in). 13. Remove the 2 nuts and the front door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 14. To install, reverse the removal procedure. Master Window/Door Lock/Unlock Switch Page 6856 This program involves lowering the headliner enough to inspect the structural foam blocks which are mounted above the front corners of the headliner. Depending on the results of the inspection, dealers will either release the vehicle, or modify the structural foam blocks using a special tool and a 5/8 inch auger bit. See Figure 1. SERVICE PROCEDURE CAUTION: Failure to perform all disassembly steps as outlined increases the possibility of damaging the headliner. CAUTION: Make sure your hands are clean before performing this repair. NOTE: Although the headliner does not have to be removed to carry out the inspection or modification, a number of trim panels and components must be removed or repositioned in order to lower the front of the headliner for access. Performing all steps as outlined will position the headliner adequately for access to the repair area. NOTE: If the vehicle is equipped with any aftermarket or dealer-installed options, such as a DVD player that interferes with adequately lowering the headliner, they must be removed. DISASSEMBLY FOR INSPECTION NOTE: Perform the following steps on both sides of the vehicle. 1. Open the A-pillar assist handle bolt covers, then remove the bolts and the assist handles. 2. Remove the A-pillar trim panels. 3. At the B-pillars, remove the D-ring covers and the safety belt bolts. 4. Remove the upper B-pillar bolt covers and the bolts, then remove the B-pillar trim panels. 5. If equipped, remove the overhead console retaining screws and disconnect the electrical connector, then remove the console from the vehicle. 6. Remove the sunvisors and sunvisor clips. If equipped, disconnect the electrical connectors. 7. Open the rear seat overhead assist handle bolt covers, then remove the bolts and the assist handles. 8. Position the front and rear door weatherstrips down away from the headliner. 9. Allow the headliner to hang down loosely at the front corners. Do not pull down on the headliner or otherwise stress it, or damage may result. INSPECTION Page 7450 90-3 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 Service and Repair Windshield Washer Hose: Service and Repair WASHER HOSE REPAIR 1. Locate and verify the leaking washer hose. 2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a windshield washer hose adapter between the cut ends of the hose. 4. NOTE: In difficult cases, clamping may be required. Install a segment of 6.4 mm (0.25 in) i.d. black rubber hose over the ends of the washer hose, and clamp both ends of the rubber hose using spring clamps. Page 4332 Page 6887 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer P0106 P0106 Page 1658 Page 166 P0234 Page 618 P1462 Service and Repair Body Control Module: Service and Repair SMART JUNCTION BOX (SJB) Removal and Installation 1. CAUTION: Prior to removal of the SJB, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery. 2. Remove the floor console SJB cover. 3. Remove the transmission selector lever bezel from the floor console finish panel. 4. Apply the parking brake. 5. Remove the parking brake lever boot from the floor console finish panel. 6. Remove the floor console finish panel. Page 6989 12. Remove the two nuts at the lift links, then remove the seat position sensor and bracket. 13. NOTE: - The drive tube is press-fit to stub shafts on each end. A hammer may be necessary to separate the drive tube. - The drive tube must be clamped at the inboard track gear stub shaft to allow the drive tube to separate at the seat track motor gear stub shaft. Clamp the locking pliers on the flats of the drive tube where it reaches over the inboard track gear stub shaft. Tap on the locking pliers, separate the drive tube from the seat track motor assembly stub shaft and remove the inboard track and drive tube. 14. Remove the two nuts. 15. Remove the outboard retainer clip. Page 7804 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Diagram Information and Instructions Daytime Running 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 4399 Output Yoke/Flange: Service and Repair Transfer Case Rear Output Shaft Flange Dust Shield Transfer Case Rear Output Shaft Flange Dust Shield Special Tool(s) Removal 1. Remove the transfer case rear output shaft flange. Refer to Transfer Case Rear Output Shaft Flange. 2. Remove the transfer case rear output shaft flange dust shield. Installation 1. Using the special tool, snap the dust shield onto the transfer case rear output shaft flange. 2. Install the transfer case rear output shaft flange. Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 5343 Rear Subframe: Service and Repair REAR SUBFRAME Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with 4WD 2. Remove the rear axle assembly. All vehicles Output Shaft Speed (OSS) Sensor Page 631 P1479 Page 5624 4. Disconnect the 2 evaporator core spring lock couplings. 5. NOTE: Carefully remove the evaporator core housing to avoid spilling PAG compressor oil in the passenger area. Remove the 4 evaporator core housing nuts and the evaporator core housing. 6. NOTE: - Feed the vacuum hose through the opening in the cowl while installing the housing. - Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. 7. Evacuate, leak test and charge the refrigerant system. Page 5410 Page 6411 Page 6900 Power Door Lock Actuator: Diagrams Door Lock Actuator Page 3064 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. To install, reverse the removal procedure. Locations Specifications Axle Nut: Specifications Wheel hub nut Tighten to ............................................................................................................................................. ........................................... 290 Nm (214 ft. lbs.) Locations View 151-7 (Engine, front) Driver Side View 151-20 (Driver Seat) Page 1830 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the A/C refrigerant. 3. Remove the 2 compressor manifold and tube assembly bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the spring lock coupling from the suction accumulator. 5. Remove the front bumper cover. 6. Disconnect the condenser core peanut fitting. - Remove the condenser core peanut fitting nut. To install, tighten to 8 Nm (71 lb-in). 7. Remove the RH splash shield. 8. If equipped, disconnect the engine block heater. 9. Disconnect the A/C compressor electrical connector. 10. Remove the manifold and tube assembly bolt. - To install, tighten to 20 Nm (15 lb-ft). 11. Remove the A/C compressor manifold and tube assembly. - Remove and discard the O-rings. 12. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. Page 2442 2.0L Focus (with A/C) And Taurus/Sable: PCM FC Output State For Cooling Fan Speeds Chart 2.0L Escape: PCM FC Output State For Cooling Fan Speeds Chart Freestar, Monterey: PCM FC Output State For Cooling Fan Speeds Chart For 3-speed fans, although the PCM output circuits are called low, medium, and high tan control (FC), cooling fan speed is controlled by a combination of these outputs. Refer to the table. Page 1245 Page 4887 Page 3018 H11-H14 Normal Operation The high speed CAN has an unshielded twisted pair cable, circuits 1908 (WH) and 1909 (BK). The powertrain control module (PCM), anti-lock brake system (ABS) module, four-wheel drive (4WD) control module, and the instrument cluster are all on the high speed CAN. Total network resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the high speed CAN circuits, damage to the data link connector (DLC) C251, damage to one of the network module connectors, or damage to an in-line connector. Since both the PCM and the instrument cluster share network termination responsibilities, a problem in either of these modules can result in a high speed CAN failure. Possible Causes - high speed CAN circuits 1908 (WH) and 1909 (BK) shorted to ground or open - PCM - instrument cluster - ABS module - 4WD control module Test I: No Module/Network Communication - No Power to The Diagnostic Tool PINPOINT TEST I: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL A/T - Shifter Release Button Cap Falls Off Shifter CVT: All Technical Service Bulletins A/T - Shifter Release Button Cap Falls Off TSB 05-4-5 03/07/05 SHIFTER RELEASE BUTTON CAP FALLS OFF FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Mariner and Escape Hybrid vehicles may exhibit a loose gear selector button cap. The button cap may fall off, and will not stay in place when re-seated. ACTION Replace the gear selector button cap only, it is not necessary to replace the entire gear selector lever. For additional information, see the latest Escape/Mariner Workshop Manual CD, Section 307-05 Selector Lever Button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050405A 2005 Escape/Escape 0.2 Hr. Hybrid/Mariner: Replace Shifter Button DEALER CODING CONDITION BASIC PART NO. CODE 7C488 33 Disclaimer Page 7537 Symbols Part 2 Page 2968 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the 3 screws, the pin-type retainer and the upper and lower snow shield. - To install, tighten to 10 Nm (89 lb-in). 3. Disconnect the idle air control (IAC) valve electrical connector. 4. Remove the 2 bolts and the IAC valve. - To install, tighten to 4 Nm (35 lb-in). - Inspect the gasket and install new as necessary. 5. To install, reverse the removal procedure. Page 5817 1. Depower the system. 2. Remove the steering wheel access cover. 3. Disconnect the 2 electrical connectors to the clockspring. 4. Loosen the steering wheel mounting pinion shaft to release the steering wheel from the steering column shaft. - To install, tighten to 16 Nm (12 lb-ft). 5. Remove the steering wheel. 6. Remove the screws and the steering wheel front cover. 7. Remove the nuts and the steering wheel armature. - To install, tighten to 16 Nm (12 lb-ft). 8. Disconnect the steering wheel accessories and remove the driver air bag module. 1 Disconnect and slide the connector off the wire shield. 2 Route the wire harness out of the wire shield. 3 If equipped, remove the screws. 4 If equipped, separate the switches from the steering wheel. 5 Lift the driver air bag module out of the steering wheel. 9. To install, reverse the removal procedure. 10. Repower the system. Page 5334 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Locations Page 1925 Power Steering Fluid: Specifications Power Steering Fluid Type ................................................................................................................................................ Motorcraft MERCON(R) ATF System Diagnosis P074x Left Front Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Locations View 151-4 (Engine Compartment, 2 Of 2) Page 6716 - To install, tighten to 200 Nm (148 lb-ft). 21. Support the front subframe and remove the 2 front subframe nuts. - To install, tighten to 150 Nm (111 lb-ft). All vehicles 22. NOTE: The lower control arm ball joints must be disconnected from the spindles at the same time the subframe is lowered. With an assistant, remove the front subframe. 23. To install, reverse the removal procedure. Turn Lamp Turn Signal Lamp: Diagrams Turn Lamp Diagrams Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Page 4803 Page 5009 Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Page 3694 Camshaft Position Sensor: Diagrams Page 7150 Page 7822 Symptom Chart Locations Page 6467 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 4121 6. Remove the shifter. 1 Disconnect the electrical connector. 2 Remove the 4 bolts and remove the shifter. Installation 1. Install the shifter assembly. 1 Install the shifter and the 4 bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 2 Connect the electrical connector. 2. Install the upper center console assembly. Smart Junction Box Fuse: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Service and Repair Cowl Moulding / Trim: Service and Repair COWL PANEL GRILLE Removal and Installation 1. Remove the 2 wiper pivot arms nuts. - To install, tighten to 35 Nm (26 lb-ft). 2. Remove the LH and RH wiper pivot arms. 3. Remove the 8 cowl panel grille pin-type retainers. 4. Remove the 8 cowl panel grille caps and screws. 5. Remove the LH cowl panel grille. 6. Remove the RH cowl panel grille. 7. To install, reverse the removal procedure. - Adjust the wiper pivot arms. Page 1577 11. Connect the electrical connectors and wiring clips. 1 Connect the OCS ECU electrical connector. 2 Connect the pressure sensor electrical connector. 3 Install the 2 wiring clips on the wiring harness to the cushion pan. 4 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 12. Install the passenger seat into the vehicle. 13. Repower the system. Do not prove out the system at this time. 14. CAUTION: - 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Page 5381 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Spring Removal NOTE: LH is shown, RH is similar. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Support the wheel knuckle and remove the upper ball joint nut. 3. Remove the lower shock absorber nut, washer, and bolt. 4. Remove the upper arm inner bolt. ^ Loosen the lower arm inner bolt. 5. NOTE: Note the position of the coil spring insulator and coil spring for installation. Carefully lower the wheel knuckle support. 6. Remove the coil spring. Installation 1. Align the coil spring and coil spring insulator to the previously noted position. 2. Carefully raise the wheel knuckle support. 3. Install the upper arm inner bolt. ^ Tighten the upper and lower arm inner bolts to 115 Nm (85 ft. lbs.). 4. Install the lower shock absorber bolt, washer, and nut. ^ Tighten the nut to 175 Nm (129 ft. lbs.). 5. Install the upper ball joint nut and remove the wheel knuckle support. ^ Tighten the nut to 103 Nm (76 ft. lbs.). Page 7489 Symbols Part 4 Page 1109 Page 3892 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. Locations View 151-10 (Automatic Transmission) Service and Repair Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 2175 2006-2007 Mariner Hybrid 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A Operation A: 2001-2007 2.0 Hrs. Ranger 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) DEALER CODING CONDITION BASIC PART NO. CODE 6312 D4 Disclaimer Page 658 P1518 Locations Locations Page 525 P1246 Page 7216 66-2 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 Diagram Information and Instructions Shift Interlock: 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 4986 Heated Seat Module, Driver Side Front View 151-20 (Driver Seat) Page 4361 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Windshield Washer Pump and Reservoir - Exploded View Windshield Washer Pump: Service and Repair Windshield Washer Pump and Reservoir - Exploded View WIPER AND WASHER SYSTEM - EXPLODED VIEW, WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. For additional information, refer to the procedures. Page 5719 1. Check for leaks using an approved UV lamp. - Inspect all the 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 an approved UV lamp. Fluorescent Dye Injection - Using an A/C 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 an 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. New 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 manufacturer 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 refrigerant 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. - The 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 center or a manifold and gauge set to the refrigerant system port valves. 2. Verify that the valves on the fluorescent dye injector are closed. System Diagnosis P077x Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the heated oxygen sensor (HO2S) electrical connector. Page 4272 Shifter M/T: Service and Repair Gearshift Cables Gearshift Cables Removal 1. Remove the floor console. Page 4283 3. Connect the gearshift cable. 4. Install the 2 gearshift cable grommet nuts. ^ Tighten to 10 Nm (89 inch lbs.). 5. CAUTION: Make sure the clips are set completely within the cable adapter groove and fully seated. Install the 2 gearshift cable clips. 6. Connect the gearshift cables to the transaxle gearshift control assembly. 7. Adjust the gearshift cables. 8. Install the floor console. Page 1271 Ambient Light Sensor: Service and Repair LIGHT SENSOR Removal and Installation 1. Remove the sensor from the instrument panel. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 5697 Condenser Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Remove the RH splash shield. 5. If equipped, disconnect the block heater electrical connector. 6. Remove the compressor to condenser discharge line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the compressor to condenser discharge line from the compressor. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the condenser core peanut fitting nut and disconnect the condenser core peanut fitting compressor. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor to condenser discharge line. 10. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 4711 Page 7491 Courtesy 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 - Whine Noise at 20-45 MPH Axle Shaft Assembly: All Technical Service Bulletins Drivetrain - Whine Noise at 20-45 MPH TSB 05-10-7 05/30/05 DRIVELINE WHINE 20-45 MPH (32-72 KM/H) FORD: 2001-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2001-2006 Escape and 2005-2006 Mariner vehicles equipped with a CD4E transaxle may exhibit a driveline whine at 20-45 MPH (32-72 Km/h) during light acceleration or deceleration. The sound may be more pronounced on vehicles equipped with steel wheels. ACTION If the whine noise occurs at the specified speed range 20-45 MPH (32-72 Km/h) during light acceleration or deceleration, install new dampened halfshaft assemblies. The revised halfshafts are designed to minimize the whine, however, a small amount of noise may be inherently characteristic. The dampened axle halfshafts will not correct driveline noises below or above 20-45 MPH (32-72 Km/h). Refer to Workshop Manual Section 307. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051007A 2001-2004 Escape 1.1 Hrs. Replace The Front Halfshafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) 051007B 2005-2006 Escape/Mariner 1.4 Hrs. Replace The Front Half shafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) DEALER CODING CONDITION BASIC PART NO. CODE 3A427 42 Disclaimer Page 1943 Refrigerant: Service and Repair Refrigerant Identification Testing REFRIGERANT IDENTIFICATION TESTING 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 1 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 the 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 the hydrocarbon concentrations are 2% or greater by weight, the red FAIL LED will light, Hydrocarbon High 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 the 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 1914 Fluid - Transfer Case: Service and Repair Manual Transaxle Transfer Case Draining and Filling-Manual Transaxle Material CAUTION: New transfer case lubricant must be installed any time the transfer case has been submerged in water. NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected. To drain the transfer case fluid, the transfer case must be removed from the vehicle. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Transfer case failure can result if the correct fill procedures are not followed. NOTE: The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground. Remove the fill plug and fill the transfer case with rear axle lubricant. 3. Install the fill plug and gasket. ^ Tighten to 49 Nm (36 ft. lbs.). Page 205 P0295 - P0299: Testing and Inspection P0298 P0298 (Part 1) P0298 (Part 2) Page 2335 Smart Junction Box Fuse: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 6165 Accessory Delay Relay: Testing and Inspection Page 6979 Page 7497 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. Locations View 151-3 (Engine Compartment, 1 Of 2) Page 959 GEN II ETC System The torque based ETC strategy was developed to improve fuel economy and to accommodate variable cam timing (VCT). This is possible by not coupling the throttle angle to the driver pedal position. Uncoupling the throttle angle (produce engine torque) from the pedal position (driver demand) allows the powertrain control strategy to optimize fuel control and transmission shift schedules while delivering the requested wheel torque. The ETC monitor system is distributed across 2 processors within the PCM: the main powertrain control processor unit (CPU) and a monitoring processor called an enhanced-quizzer (E-Quizzer) processor. The primary monitoring function is carried out by the independent plausibility check (IPC) software, which resides on the main processor. It is responsible for determining the driver-demanded torque and comparing it to an estimate of the actual torque delivered. If the generated torque exceeds driver demand by a specified amount, the IPC takes appropriate corrective action. Page 6291 C5-C6 Normal Operation The instrument cluster sends a signal to the message center INFO switch on circuit 1411 (GY/OG), and to the message center SET switch on circuit 1410 (TN/OG), which communicates the requested switch function to the message center. The switches are grounded through circuit 570 (BK/WH). Possible Causes - circuit 570 (BK/WH) open - circuit 1411 (GY/OG) open or short to ground - circuit 1410 (TN/OG) open or short to ground - message center SET switch - message center INFO switch - instrument cluster Test D: The Compass Is Inoperative PINPOINT TEST D: THE COMPASS IS INOPERATIVE D1 Specifications Clutch Fluid: Specifications Clutch Fluid Type .................................................................................................... Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Page 7481 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 7225 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 Locations View 151-7 (Engine, front) P2126 P2126 Page 6948 P1245 P1245 - P1249: Testing and Inspection P1245 P1245 (Part 1) P1245 (Part 2) Locations View 151-10 (Automatic Transmission) Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE PIPE Page 4151 6. Using the special tool, remove the seal. Installation 1. NOTE: Make sure that the mating surface is clean before installing the new seal. Using the special tool, install the seal. 2. NOTE: Lubricate the pinion flange with premium long-life grease. Line up the index marks and position the pinion flange. 3. Using the special tool, install the pinion nut. ^ Tighten to 244 Nm (180 ft. lbs.). Page 3460 - Remove and discard the 8 fuel injector O-ring seals. Installation 1. 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. NOTE: Install new fuel injector O-ring seals and lubricate them with clean engine oil. Install the fuel injectors and the retainer clips. 2. Position the fuel rail spacers and the fuel rail. 3. Install the fuel rail bolts and attach the wiring retainers. - Tighten to 23 Nm (17 lb-ft). 4. Connect the fuel injector electrical connectors. 5. Connect the fuel rail pressure and temperature vacuum tube and electrical connector. 6. NOTE: - Make sure the collar on the fuel tube is inserted fully into the quick release coupling before the locking tang is locked. - Apply clean engine oil to the end of the tube before inserting a tube into the connector. Connect the fuel tube quick release coupling. Connect the quick lock coupling to the tube. - Press the quick connect coupling locking tangs into position. - Pull on the fitting to make sure it is fully engaged. 7. Connect the battery ground cable. Page 7283 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a fixed format LCD display, integrated into the instrument cluster. The message center functions are controlled by the message center switches. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Page 7372 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. Page 2656 Page 7397 Fuel Gauge Sender: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 6183 Page 1110 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Page 2939 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 6479 B1342-B2070 Page 4533 Brake Bleeding: Service and Repair Gravity Bleed Gravity Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RR wheel, to the LR wheel, to the RF wheel, and ending with the LF wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Loosen the bleeder screw and leave it open until clear, bubble-free brake fluid flows. 5. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the brake hydraulic system at each wheel. 7. Fill the brake master cylinder reservoir with the specified brake fluid. Page 1723 Difference From Standard Position (RH Side) 6. Install and tighten the front strut upper mounting bracket nuts. Page 6915 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: LH side shown, RH side similar. 1. Remove the front door trim panel. 2. On Mariner vehicles, remove the 3 screws and the front door trim panel arm rest. 3. Release the bezel retaining clip from the door trim panel. 4. Release the locking clips and remove the window control switch. 5. To install, reverse the removal procedure. Page 2408 2. If compression does not improve, valves are sticking or not seating correctly. 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 3425 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator FUEL PRESSURE REGULATOR Fuel Pressure Regulator The fuel pressure regulator is attached to the fuel rail downstream of the fuel injectors. It regulates the fuel pressure supplied to the fuel injectors. The regulator is a diaphragm-operated relief valve. One side of the diaphragm senses the fuel pressure and the other side is connected to the intake manifold vacuum. Fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the fuel injectors. Fuel pressure is high when engine vacuum is low. Excess fuel is bypassed through the fuel pressure regulator and returned through the fuel return line to the fuel tank. SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: Customer Interest SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Service and Repair Front Door Window Regulator: Service and Repair FRONT DOOR WINDOW REGULATOR Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the front door trim panel bracket. 3. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Connect the battery. 6. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 7. Disconnect the battery. 8. Disconnect the window control switch electrical connector. 9. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 10. Support the front door window glass in the full up position. 11. Disconnect the front door window motor electrical connector. 12. Remove the 3 front door window regulator and motor bolts. - To install, tighten to 6 Nm (53 lb-in). 13. Remove the 2 nuts and the front door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 14. To install, reverse the removal procedure. Page 7546 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 Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 822 P2197 Diagrams Page 1726 6. Rotate the front wheel spindle tie-rods to increase or decrease the front toe. 7. CAUTION: Hold the tie-rod end stationary with a wrench while tightening the nut, or damage to the boot can occur. NOTE: Do not disturb the toe settings while tightening the nut(s). Tighten the tie-rod end jam nut(s). 8. Install the steering gear bellows clamp(s). 9. Check the toe settings. Follow the equipment manufacturer's instructions. Rear Rear Toe Adjustment 1. CAUTION: The cam nut and cam bolt area must be free of debris to ensure proper clamping. NOTE: Clean the general area of the joint to prevent debris from entering the joint. Clean the area using only mild liquids. NOTE: Jounce the vehicle to make sure that the suspension is in its normal, at-rest position. Check the toe setting using suitable wheel alignment equipment. Master Window/Door Lock/Unlock Switch Page 3757 Page 3022 Information Bus: Testing and Inspection Module Configuration Initial Inspection MODULE CONFIGURATION Definition of Terms Calibration Update: Some modules are designed to be flashed or reflashed with complete new software packages. This process of reflashing the module is a calibration update. Programmable Parameters: These are options contained within the existing software. These include items such as tire size, customer preference items, and anti-theft options. The current settings are downloaded from an existing module then uploaded to a new module. They can also be configured using the diagnostic tool. Programming parameters is very different from updating calibrations as no software is changed, only the options already contained in the software. Module Programming Methods Some modules must be programmed as part of the repair procedure. If this procedure is not followed, the module will not function correctly and may set a number of diagnostic trouble codes (DTC)s, including B2477 or P1639, which indicate that some necessary data has not been programmed into the module. Modules that need programming should not be exchanged between vehicles. In most cases the parameter values or settings are unique to that vehicle, and if not set correctly cause concerns or faults. The Worldwide Diagnostic System (WDS) automatically attempts to retrieve the module configuration information from all modules. If the module cannot communicate, the diagnostic tool either requests the As-Built data or displays a list of items that need to be manually configured. The WDS programs the module based on the data entered. For diagnostic tool information, refer to the general procedures. There are 3 different methods that are used for module programming: programmable module installation (PMI) - calibration update - programmable parameters Some modules do not support all 3 methods. Programmable Module Installation (PMI) The PMI method is used when a new, programmable module is installed in the vehicle. It is no longer necessary to command the diagnostic tool to gather module option content from the old module. The diagnostic tool (WDS only) automatically obtains any available module option content information from the old module during the vehicle ID routine that runs when the diagnostic tool is initially connected to the vehicle. It is important to connect the WDS to the vehicle and allow it to identify the vehicle and obtain configuration data prior to removing any modules. Calibration Update Calibration update is used to install a new calibration and strategy into a module. Programmable Parameters This method is used to configure parameters that may be modified. Not all features controlled by the module are listed in this configuration method. Refer to the Programmable Parameters Index for a list of features by system. If a module that has been modified using programmable parameters needs to be installed, the PMI procedure maintains the parameters in their altered state if the WDS is able to communicate with the old module during vehicle ID. Otherwise, programmable parameters may be needed to return them to the altered state. Vehicle Identification (VID) Block Some powertrain control modules (PCM)s contain a memory area called a VID block. The PCM VID block may contain the factory settings for the configurable modules unless the PCM is flashed with a new calibration, in which case some PCM parameters may be modified. As-Built Data Center The As-Built Data Center maintains a record of the vehicle configuration in a database. The vehicle identification number (VIN) is required to obtain this information. The As-Built Data Center records the applicable module configurations stored in each module before the vehicle leaves the factory. The As-Built Data Center always reflects the original build of the vehicle as it left the factory. Only contact the As-Built Data Center when directed to do so by the diagnostic tool. Locations View 151-13 (Behind Dash Panel) Page 6100 2. NOTE: Mark the hood latch position prior to removal of the bolts. Position the hood latch assembly aside. 1 Loosen the hood latch nut. 2 Remove the hood latch bolts. 3 Position the hood latch aside. 3. Detach the wiring harness pin-type retainers. 4. Remove the radiator support bracket bolt. 5. Remove the front impact severity sensor bolt. 6. Disconnect the electrical connector and remove the front impact severity sensor. Installation 1. Connect the electrical connector to the front impact severity sensor. 2. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Align the locator tabs of the front impact severity sensor to the openings in the radiator support bracket. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. Install the front impact severity sensor bolt. Tighten to 12 Nm (9 lb-ft). 4. Install the radiator support bracket bolt. - Tighten to 12 Nm (9 lb-ft). 5. Attach the wiring harness pin-type retainers. Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 6575 Disclaimer Page 7655 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 7088 Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUGS Exploded View Removal 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connectors. 3. Remove the bolts and the ignition coils. 4. NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. Remove the spark plugs. Installation Page 3187 View 151-8 (Engine, rear) Page 4150 2. Remove the rear driveshaft universal joint caps. 1 Index-mark the pinion and pinion flange to the rear of the driveshaft. 2 Remove the 4 bolts and the 2 cap straps. ^ Support the driveshaft. 3. NOTE: Discard the nut after removing it. Install a new nut during installation. Using the special tool, hold the pinion flange while removing the nut. ^ Remove the nut. 4. Index-mark the location of the pinion to the yoke. 5. Using the special tool, remove the pinion flange. Page 2730 Throttle Position Sensor: Diagrams Page 3928 6. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 7. Move the shifter through all gears from PARK to DRIVE several times making sure that the screw is not too tight. Page 5486 Wheel Fastener: Service and Repair Rear Removal and Installation 1. Remove the wheel bearing and hub. 2. Using a suitable press, remove the wheel studs from the wheel hub. 3. To install, reverse the removal procedure. Page 6143 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 electronic control unit (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 OEM OCS, refer to the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate Page 1637 View 151-10 (Automatic Transmission) Page 3885 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 2018 Page 5264 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Page 6936 Exterior Paint Exterior paint codes may be listed as a two-part code. The first set of characters identify the primary body color. The second set of characters (if applicable) identify the vehicle accent or two-tone body color. Exterior Color Codes C2 - Gold Ash Metallic - CX - Dark Shadow Gray (clearcoat) - DV - Light Tundra - G2 - Redfire - GW - Fossil Orange - KR - Norcea Blue Pearl - R1 - Dark Teal (clearcoat) - SN - Sonic Blue (clearcoat) - T5 - Dark Copper Metallic - UA - Ebony (clearcoat) - YN - Silver Metallic (clearcoat) - YZ - Oxford White (clearcoat) Interior Trim Fuel Rail Pressure/Temperature Sensor Page 4280 Shifter M/T: Service and Repair Gearshift Lever Boot Gearshift Lever Boot Removal and Installation CAUTION: The gearshift lever boot and gearshift lever knob is one assembly. 1. Separate the gearshift lever boot from the floor console. 2. NOTE: The gearshift lever boot has been removed for clarity. Cut the gearshift lever knob crimp ring. 3. Remove the gearshift lever knob and gearshift lever boot assembly. 4. CAUTION: A fully seated knob will conceal the knurled section on the gearshift lever. Failure to fully seat the gearshift knob may cause gearshift lever boot damage. To install, reverse the removal procedure. ^ Crimp the ring to 40 Nm (30 ft. lbs.). Page 7171 P2065 P2065 Page 5880 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the B-pillar trim panel. 3. Disconnect the side impact sensor electrical connector. 4. Remove the bolt and the side impact sensor. Installation Page 4882 System Diagnosis P09xx Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE PIPE 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 Fuel Rail Pressure/Temperature Sensor Page 6698 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Locations View 151-8 (Engine, rear) Output Shaft Speed (OSS) Sensor Page 7189 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 hardwire connection, based on information provided by the occupant classification sensor (OCS) system. The PAD indicator is lit to indicate the passenger air bag module is disabled. An exemption to this is 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 other cases, the PAD indicator is unlit when the passenger air bag module is enabled. 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 correct functional operation of the PAD indicator. The PAD indicator will lit/unlit within 1.0 to 1.5 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 enabled regardless of the size of the occupant in the front outboard passenger seat. The PAD indicator will be unlit. Passenger Air Bag PAD Indicator Status The table indicates the passenger air bag status and the PAD indicator status based the size of the front outboard passenger occupant. Page 6450 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 1518 Page 539 P1267 Page 3927 1. Install the gearshift bezel. 2. Feed the overdrive cancel switch electrical connector wire harness into the opening in the dash and install the knob. 3. CAUTION: Do not overtighten the set screw or damage to the plastic straw will occur. Install the set screw. 4. Connect the overdrive cancel switch electrical connector. 5. Install the top finish panel. Locations Page 1135 P2257 P2257 P1130 P1130 - P1134: Testing and Inspection P1130 P1130 (Part 1) P1130 (Part 2) Page 4631 ^ Plug the clutch master cylinder feed hose. 5. Remove the reservoir. ^ Release the retaining clips on the underside of the reservoir. ^ Pull the reservoir upwards. 6. NOTE: Install new seals. Lubricate the seals with clean DOT 3 motor vehicle brake fluid. Remove and discard the 2 seals. 7. To install, reverse the removal procedure. ^ Bleed the brake system. ^ If equipped with a manual transmission, bleed the clutch master cylinder. Locations View 151-7 (Engine, front) Page 2068 Disclaimer System Diagnosis P075x Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Fluid Capacity .............................................................................................................. ......................................................................... 12 oz. Page 720 P1709 Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ .............................................................. 907 g (2 lb.) Page 6191 View 151-22 (Left Front Door) Page 7750 Page 3087 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts). - 2 signal return (ground) circuits. - APP1 voltage with negative voltage slope (5-0 volts). - APP2 voltage with positive voltage slope (0-5 volts). - APP3 voltage with positive voltage slope (0-5 volts). 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a fault. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value will be substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Page 1778 Exploded View Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the air cleaner intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Page 326 P0505 - P0509: Testing and Inspection P0506 P0506 (Part 1) P0506 (Part 2) Page 4818 Page 3247 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Locations View 151-3 (Engine Compartment, 1 Of 2) Steering - Front End Rattle Noise Turning On Bumps Power Steering Line/Hose: Customer Interest Steering - Front End Rattle Noise Turning On Bumps TSB 06-17-3 09/04/06 STEERING NOISE - CLUNK/RATTLE FORD: 2005-2007 Escape MERCURY: 2005-2007 Mariner This article supersedes TSB 05-25-9 to update the vehicle model years. ISSUE Some 2005-2007 Escape and Mariner vehicles may exhibit a single or multiple clunk/rattle noise from the front end. This noise typically occurs with the front wheels turned while hitting a bump such as when turning into a driveway. It is usually more noticeable with hot engine and ambient air temperatures, and may easily be mistaken for loose sheet metal or a loose suspension/underhood component. The cause of this noise is an audible hydraulic pressure spike in the power steering system. ACTION Install a new power steering return line which contains an internal orifice to reduce the pressure spike. SERVICE PROCEDURE 1. Remove the power steering reservoir cap. 2. Using a suitable suction device, remove the power steering fluid from the reservoir. 3. Disconnect the power steering return hose from the reservoir by loosening the constant tension clamp. 4. Remove and discard the lower return line hose clamp, then remove the hose. 5. Install the new return line with the crimped band away from the reservoir. The pre-installed constant tension clamp will retain the reservoir end of the hose. 6. Install and tighten the screw clamp on the lower end of the hose. 7. Refill the system with Mercon® or Mercon(R)-V fluid and purge the air as described in Section 211-00 of the Workshop Manual. NOTE DO NOT FILL WITH TYPE-F FLUID. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061703A 2005-2007 Escape/Mariner: 0.5 Hr. Replace Power Steering Return Line (Do Not Use With 3713AE) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 Page 7018 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 788 P2106 Page 8029 Wiper Motor: Service and Repair Rear Window Wiper Motor REAR WINDOW WIPER MOTOR Removal and Installation 1. Make sure the rear window wiper motor is in the PARK position. Turn the rear window wiper motor ON and allow it to operate for at least one cycle. 2. Turn the rear window wiper motor switch to OFF and mark the position of the end of the wiper blade on the back glass for reinstallation. 3. Remove the rear pivot arm. 1 Lift the pivot arm to the upright position. 2 Slide the locking tab out. 3 Pull up and remove the pivot arm. 4. Remove the rear wiper motor shaft nut cover. 5. Remove the rear wiper motor shaft nut. - To install, tighten to 7 Nm (62 lb-in). 6. Remove the rear wiper motor cover. 7. Remove the rear wiper motor bracket nut. - To install, tighten to 4 Nm (35 lb-in). 8. Remove the bolt and the rear wiper motor. - To install, tighten to 5 Nm (44 lb-in). 9. To install, reverse the removal procedure. - Adjust the rear wiper pivot arm. Page 2097 3. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. Page 7152 2. Disconnect the speed control cable from the speed control actuator pulley. 1 Gently push the retaining spring. 2 Disconnect the speed control cable slug from the speed control actuator pulley. 3. Remove the 3 speed control actuator screws and the speed control actuator. - Disconnect the electrical connector. Installation CAUTION: A new speed control cable must be installed. 1. Install the speed control actuator and the 3 speed control actuator screws. - Tighten to 9 Nm (80 lb-in). - Connect the electrical connector. 2. 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. 3. CAUTION: - It is necessary to squarely seat the speed control cable cap and seal around the speed control actuator pulley. - Incorrect wrapping of the speed control cable around the speed control actuator pulley may result in high idle conditions. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap. Align the speed control cable cap tabs with the slots in the speed control actuator housing. Replacement Brake Fluid: Service and Repair Replacement Brake Fluid Replacement WARNING: Use of any other than the approved DOT 3 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 the surface with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Do not allow the master cylinder brake fluid to overflow from the reservoir. Brake fluid may damage the high-voltage components. NOTE: Bleeding the HCU is required only when removing or installing the HCU, master cylinder, or opening the lines to the HCU. NOTE: Make sure that the brake fluid level is above the MIN mark. 1. NOTE: Adequate voltage to the HCU module is required during the system bleed. Connect the diagnostic tool. 2. Access the service bleed function. Access the service bleed function on the diagnostic tool and follow the directions. P0451 P0451 Page 533 P1264 Page 4193 14. Position the tripod housing onto the tripod. 15. Position the inner CV boot. 1 Position the inner CV boot onto the CV joint housing. 2 Position the inner CV boot clamp. 16. Adjust the inner CV boot spacing and remove any excess air trapped in the CV boot using a cloth-covered screwdriver. 17. Using the special tool, install the 2 new inner CV joint boot clamps. 18. Remove the front drive halfshaft from the vise. 19. Install the front drive front drive halfshaft. Page 3212 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Service and Repair Body Control Module: Service and Repair SMART JUNCTION BOX (SJB) Removal and Installation 1. CAUTION: Prior to removal of the SJB, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery. 2. Remove the floor console SJB cover. 3. Remove the transmission selector lever bezel from the floor console finish panel. 4. Apply the parking brake. 5. Remove the parking brake lever boot from the floor console finish panel. 6. Remove the floor console finish panel. Page 6733 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 1718 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. When the wheels are turned in toward the front of the vehicle, the toe is positive (+) (toe in). When the wheels are turned out toward the front of the vehicle, the toe is negative (-) (toe out). This is measured in degrees, from side-to-side, and totalled. Wheel Track Rear Thrust Angle ^ Rear thrust angle can be defined as a line bisecting the rear toe or simply the direction in which the rear wheels are pointed. ^ Rear thrust angle = (LR toe - RR toe). ^ If the rear wheels are pointed to the right, the thrust angle is positive; if the rear wheels are pointed to the left, the 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. Dog Tracking Dog tracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dog tracking. Shimmy Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Page 3284 Removal 1. Remove the exhaust flexible pipe. 2. Remove the 2 catalytic converter bracket bolts. 3. Remove the 6 heat shield bolts and the heat shield. Page 5806 Air Bag: Locations Side Air Curtain Module View 151-16 (Full Body, Left Rear - 2 Of 2) Page 6189 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. Service and Repair Housing Assembly HVAC: Service and Repair EVAPORATOR CORE HOUSING Removal and Installation 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 accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator. 1. Recover the refrigerant. 2. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 3. Disconnect the vacuum hose. 4. Disconnect the 2 evaporator core spring lock couplings. 5. NOTE: Carefully remove the evaporator core housing to avoid spilling PAG compressor oil in the passenger area. Remove the 4 evaporator core housing nuts and the evaporator core housing. Transfer any necessary external components from the old evaporator core housing to the new evaporator core housing. 6. NOTE: - Feed the vacuum hose through the opening in the cowl while installing the housing. - Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. - New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of PAG oil. - Evacuate, leak test, and charge the refrigerant system. Page 2896 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. P0221 P0221 Description and Operation Seat Belt Reminder Buzzer: Description and Operation Safety Belt Warning Indicator and Chime The warning indicator and chime are reminders to fasten the safety belt. The system operates as follows: 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 4 to 8 seconds with no chime. Belt Minder The Belt Minder feature is a supplemental warning to the safety belt warning function. This feature provides an additional reminder to the driver that the driver's 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 Seat Belt Systems. P0121 P0120 - P0124: Testing and Inspection P0121 P0121 (Part 1) P0121 (Part 2) Page 4956 Fuse Block: Locations Battery Junction Box Page 1492 Throttle Position Sensor: Diagrams Page 1992 Fuse Block: Locations Battery Junction Box Page 3870 Fluorescent Dye Leak Detection Refrigerant: Testing and Inspection Fluorescent Dye Leak Detection FLUORESCENT DYE LEAK DETECTION Special Tool(s) Special Tool(s) Fluorescent Dye Detection NOTE: Vehicles are manufactured 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 1 leak can exist, make sure to inspect each component, line, and fitting in the refrigerant system for a leak. Page 7087 Power Mirror Switch: Testing and Inspection Interior - Headliner Sagging Near Rear Hatch Headliner: All Technical Service Bulletins Interior - Headliner Sagging Near Rear Hatch TSB 05-8-3 05/02/05 HEADLINER SAGGING NEAR REAR HATCH FORD: 2004-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2004-2005 vehicles may exhibit the headliner sagging around the rear hatch perimeter edge. ACTION Adhere the headliner to the underside of the roof panel. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the perimeter seal near the sagging edge (Figure 1). 2. Without removing the headliner push pins, pull the headliner down far enough to scuff/sand the back side of the headliner and the underside of the roof panel. 3. Prepare the cartridge of Motorcraft Plastic Bonding Adhesive (TA-9), and apply the adhesive to the back side of the headliner (Figure 2). Page 5749 Page 2318 Page 7588 Page 6500 Symbols Part 3 Page 2649 Crankshaft Position Sensor: Diagrams Locations Page 6519 7. Remove the SJB screw. 8. Disconnect the electrical connectors and remove the SJB. 9. To install, reverse the removal procedure. - Configure the SJB. Refer to Information Bus (Module Communications Network). Page 3888 Symbols Part 4 Page 2357 10. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine. CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley it must be installed back onto the crankshaft. Remove the crankshaft pulley. ^ Remove the crankshaft pulley bolt and washer. ^ Remove the crankshaft pulley. 11. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using the special tool, remove the crankshaft front oil seal. 12. Remove the 3 bolts and the coolant pump pulley. 13. Remove the 2 power steering pump bolts. Page 7231 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 5244 6. CAUTION: Do not use a hammer to separate the outer Constant Velocity (CV) joint from the hub. Damage to the threads and internal CV joint components can result. Using the special tools, separate the outer CV joint from the wheel hub. All vehicles 7. Remove the Anti-Lock Brake System (ABS) wheel speed sensor bolt and the 2 ABS wheel speed sensor wire bolts. 8. Remove and position the wheel speed sensor and harness aside. 9. Remove the coil spring. 10. Remove the lower ball joint nut. 11. CAUTION: The joint surfaces must be clean. NOTE: Clean the general area of the joint to prevent debris from entering the joint. Clean using only mild liquids. Reference mark the notch on the cam nut adjustment cam. 12. Remove and discard the wheel knuckle bolt. 13. Remove and discard the cam nut. 14. Remove the wheel knuckle. Installation All vehicles 1. CAUTION: The joint area must be free of debris to ensure correct clamping. NOTE: The joint surfaces and the bushing sleeve serrations must be clean before assembly. Clean the joint surfaces and the bushing sleeve serrations with a wire brush. NOTE: Align the notch on the cam nut with the reference marks. Position the wheel knuckle and install a new wheel knuckle bolt and cam nut. 2. Using a suitable tool, hold the cam nut stationary while tightening the wheel knuckle bolt. ^ Tighten to 150 Nm (111 ft. lbs.). 3. Position the ABS wheel speed sensor harness and the sensor. 4. Position the lower ball joint into the wheel knuckle and install the lower ball joint nut. ^ Tighten to 103 Nm (76 ft. lbs.). 5. Install the coil spring. 6. Install the ABS wheel speed sensor bolt and the 2 ABS wheel speed sensor wire bolts. ^ Tighten to 9 Nm (80 inch lbs.). Disc brake vehicles Page 7190 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIR BAG DEACTIVATION (PAD) INDICATOR Removal and Installation 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 SRS must be fully operational and free of faults before releasing the vehicle to the customer. 1. Depower the system. 2. Detach the retaining clips and partially remove the instrument panel center trim panel. 3. Remove the passenger air bag deactivation indicator. 1 Release the red disconnect deterrent tab. 2 Disconnect the connector. 3 Release the 2 tabs (one shown). 4 Remove the passenger air bag deactivation indicator. Page 6965 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 6625 Rear Door Window Glass: Service and Repair Rear Door Window Glass REAR DOOR WINDOW GLASS Removal and Installation 1. Remove the rear door glass top run. 2. Remove the rear door window glass. 3. To install, reverse the removal procedure. - Cycle the rear door window glass to make sure it is engaged correctly. Page 6662 Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control LIFTGATE LATCH REMOTE CONTROL Removal and Installation 1. Remove the liftgate trim panel. 2. Disconnect the liftgate latch remote control actuating rods. 1 Open the clip and disconnect the liftgate window latch actuating rod. 2 Open the clip and disconnect the liftgate latch actuating rod. 3. Open the clip and disconnect the liftgate handle actuating rod. 4. Disconnect the electrical connectors. 1 If equipped, disconnect the liftgate latch actuator electrical connector. 2 Release the liftgate window latch ajar switch wiring harness locator. Locations View 151-3 (Engine Compartment, 1 Of 2) Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 5467 Page 3573 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 6504 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 Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Page 3597 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the RH lower A-pillar trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Page 7102 View 151-21 (Passenger Seat) Seat Position Sensor, Driver View 151-20 (Driver Seat) Page 3136 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Testing and Inspection Ignition Relay: Testing and Inspection Locations Fluid Filter - A/T: Locations Part 1 Of 7 Transmission Fluid Filter Location Filter is located at exploded view position number 8 internal. See Transmission Disassembly/Assembly. Page 3846 2. Remove the transaxle drain plug and drain the fluid. 3. Remove the LH halfshaft. 4. Using the special tools, remove and discard the LH differential seal. Installation 1. Using the special tool, install the LH differential seal. 2. Install the LH halfshaft. 3. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). 4. Fill the transaxle with clean automatic transmission fluid. 5. Start the engine and run through all the gears and check fluid level. 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: Page 1057 Page 3101 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the powertrain control module (PCM) stud bolt nut and position the wiring harness aside. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the 3 PCM electrical connectors. 4. Remove the stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the PCM cowl seal. 6. To install, reverse the removal procedure. Description and Operation Vacuum Brake Booster: Description and Operation Brake Booster The power brake actuation system includes a vacuum assisted brake booster, vacuum check valve and vacuum hose. The vacuum hose delivers engine vacuum to the vacuum check valve. The vacuum check valve is a one-way valve that allows engine supplied vacuum to the booster, and closes when engine vacuum is removed. The brake booster utilizes engine vacuum to reduce the amount of effort required at the brake pedal to actuate the foundation brakes. Page 7033 Seat Heater: Connector Views Page 2057 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the oil level indictor. 4. Remove the 2 bolts and the oil level indicator tube. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Remove and discard the oil level indicator tube O-ring seal. 6. To install, reverse the removal procedure. ^ Lubricate a new O-ring seal with clean engine oil. P0315 P0315 Page 7022 Symbols Part 4 Page 4968 Testing and Inspection Clutch Master Cylinder: Testing and Inspection Clutch Master Cylinder Check 1. Check the clutch master cylinder for leaks. Specifications Torque Specifications Page 6224 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 3861 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 4544 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Material Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Install new copper washers. Remove the brake caliper jounce hose flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 4. Remove the brake caliper. 5. To install, reverse the removal procedure. ^ Bleed the brake system. Page 2067 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 4507 3. Disconnect the electrical connector by rotating the protective cover. 4. Remove the brake line-to-HCU fittings. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. Remove the 3 HCU bracket-to-frame bolts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 6. Remove the 3 ABS module screws. ^ To install, tighten to 2 Nm (18 inch lbs.). 7. Remove the ABS module. 8. Remove the 3 bracket-to-HCU bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 9. Remove the HCU. 10. To install, reverse the removal procedure. ^ Bleed the brake system. Page 4310 Locations Page 1526 Impact Sensor: Locations Side Impact Sensor View 151-16 (Full Body, Left Rear - 2 Of 2) Page 5832 Front Wheel Fastener: Service and Repair Front Wheel Studs Removal and Installation 1. Remove the wheel bearing and hub. 2. Using a suitable press, remove the wheel stud from the wheel hub. 3. To install, reverse the removal procedure. Page 5942 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 893 View 151-13 (Behind Dash Panel) Page 5918 2. 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 component failure. - 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. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening. 3. NOTE: - When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used. - Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 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. Page 5098 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. When the wheels are turned in toward the front of the vehicle, the toe is positive (+) (toe in). When the wheels are turned out toward the front of the vehicle, the toe is negative (-) (toe out). This is measured in degrees, from side-to-side, and totalled. Wheel Track Rear Thrust Angle ^ Rear thrust angle can be defined as a line bisecting the rear toe or simply the direction in which the rear wheels are pointed. ^ Rear thrust angle = (LR toe - RR toe). ^ If the rear wheels are pointed to the right, the thrust angle is positive; if the rear wheels are pointed to the left, the 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. Dog Tracking Dog tracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dog tracking. Shimmy Shimmy, as experienced by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. Page 4694 Page 6786 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 2319 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 5844 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Position the RCM and install the 3 bolts. Tighten to 11 Nm (8 lb-ft). 2. Connect the small RCM electrical connector. 3. Make sure the connector position assurance lever is in the full release position before attempting to connect the large RCM electrical connector. 4. CAUTION: Putting the large RCM electrical wiring 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 wiring connector into the RCM. - CAUTION: Do not push the connector to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. 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 3332 Service and Repair Tie Rod End: Service and Repair Tie Rod End-Outer Special Tool(s) Removal and Installation 1. NOTE: RH side shown, LH side is similar. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the cotter pin and the tie-rod end nut. ^ To install, tighten to 55 Nm (41 ft. lbs.). 3. Loosen the tie-rod end jam nut. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Using the special tool, separate the outer tie-rod end from the front wheel knuckle. 5. Remove the tie-rod end. 6. To install, reverse the removal procedure. ^ Adjust the front toe. Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand 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 IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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. Service and Repair Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Material Page 1116 System Diagnosis P1229 Page 1438 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 641 P1500 - P1504: Testing and Inspection P1502 P1502 (Part 1) P1502 (Part 2) P0147 P0147 P0405 P0405 Page 6992 3. WARNING: The support straps are load-bearing components during a crash event. The support straps must be correctly installed during assembly of the seat track. Failure to follow these instructions may result in the failure of the seat to perform as designed with resultant risk of personal injury to the vehicle occupant. Install the support straps. The support straps must fit flush against the front and rear height adjustment gears. 4. Check to make sure the index marks on the outboard track C-channel and plastic coated slide are still in alignment. 5. WARNING: The pinion cage is a load-bearing component during a crash event. The pinion cage must be correctly installed during assembly of the seat track. Failure to follow this instruction may result in the failure of the seat to perform as designed with resultant risk of personal injury to the vehicle occupant. Position the pinion cage onto the outboard track. 6. Install the outboard track. 1 Position the track studs through the seat track motor assembly. Page 5403 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Removal and Installation NOTE: LH is shown, RH is similar. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the rear quarter trim panel. 3. Remove the upper shock absorber nuts, washer, and bushing. ^ To install, tighten to 18 Nm (13 ft. lbs.). 4. Remove the lower shock absorber nut, washer, and bolt. ^ To install, tighten to 175 (129 ft. lbs.). 5. Remove the shock absorber and the bushing. 6. To install, reverse the removal procedure. Page 158 P0222 Page 2712 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the catalyst monitor sensor. To install tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the catalyst monitor sensor. To install, reverse the removal procedure. Page 2146 1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area. ^ If excessive pitting or damage is present, install new components as necessary. Camshaft Lobe Lift Special Tool(s) 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Camshaft Runout Special Tool(s) Page 1996 Diagram Information and Instructions Shift Interlock: 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 Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Testing and Inspection Clutch Disc: Testing and Inspection Clutch Disc Check Special Tool(s) 1. Check the clutch disc lining surface for hardening or the presence of oil. 2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a slide caliper. 3. Check for loose clutch disc lining rivets. 4. Using the special tool, check the maximum allowable runout of the clutch disc. 5. Use an emery cloth to remove minor imperfections in the clutch disc lining surface. 6. Check for wear or rust on the splines. If necessary, clean them with an emery cloth. 7. Check the clutch disc for cracking, scoring, discoloration or other surface marks. Install a new clutch disc if necessary. Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Material Page 2471 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. Page 3068 Power Steering Pressure Switch: Diagrams Page 7009 Seat Cushion: Service and Repair Disassembly and Assembly REAR SEAT CUSHION Disassembly and Assembly 1. Remove the rear seat cushion. 2. Separate the J-strip and unzip the 2 zippers on each side of the cover and remove the rear seat cushion cover. 3. Remove the rear seat base cushion. 4. Remove the rear seat base. 5. Remove the 2 bolts and the rear seat base bracket. - To install, tighten to 40 Nm (30 lb-ft). 6. To assemble, reverse the disassembly procedure. Transmission Range (TR) Sensor View 151-10 (Automatic Transmission) Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 2148 Camshaft: Service and Repair Camshafts Camshafts Special Tool(s) Material Removal 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Check the valve clearance prior to removal of the camshafts. 3. Remove the timing chain and sprockets. 4. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference. 5. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts. Page 57 P0117 Page 2666 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Locations View 151-8 (Engine, rear) Page 1583 2. 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 component failure. - 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. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening. 3. NOTE: - When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used. - Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 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. Locations View 151-14 (Under Dash Panel, LH Side) Page 4801 Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 3673 Four-Tower Coil Packs The PCM provides a grounding switch for the coil primary circuit. When the switch is closed, voltage is applied to the coil primary circuit. This creates a magnetic field around the primary coil. The PCM opens the switch, causing the magnetic field to collapse, inducing the high voltage in the secondary coil windings and firing the spark plug. The spark plugs are paired so that as one spark plug fires on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil is fired the order is reversed. The next pair of spark plugs fire according to the engine firing order. Page 6346 Speaker: Diagrams Tweeter Page 4923 Seat Position Sensor, Driver View 151-20 (Driver Seat) Page 1165 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. Page 3988 2. Position the brace in place and install the nut. ^ Tighten to 150 Nm (111 ft. lbs.). 3. Install the 2 bolts for the brace. ^ Tighten to 90 Nm (66 ft. lbs.). 4. Install the bolt for the mount. ^ Tighten to 115 Nm (85 ft. lbs.). 5. Install the cross brace and the 4 bolts. ^ Tighten to 48 Nm (35 ft. lbs.). Page 6432 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. Diagrams Crankshaft Main Bearing Seal: Diagrams Lower End Components-Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Page 2235 Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply. 5. NOTE: Place all parts in order to one side. Apply compressed air to the cylinder and remove the valve spring. ^ Using the special tools, compress the valve spring and remove the valve collet, using some grease and a small screwdriver. ^ Remove the valve spring retainer and the valve spring. Installation 1. NOTE: Check the seating of the valve collet. Using the special tools, install the valve spring. ^ Insert the valve spring and the valve spring retainer. ^ Compress the valve spring and install the valve collet using some grease and a small screwdriver. 2. NOTE: Do not tighten the spark plug at this time. Disconnect the compressed air supply and install the spark plug. 3. Repeat the appropriate removal and installation steps for all of the other cylinders. 4. Tighten the spark plugs to 15 Nm (11 ft. lbs.). 5. Coat the valve tappets with clean engine oil and insert them. 6. Install the camshafts. Page 70 P0127 Page 4420 Seals and Gaskets: Service and Repair Transfer Case Driven Gear Seal Transfer Case Driven Gear Seal Special Tool(s) Removal 1. Remove the transfer case. 2. Remove the transfer case vent tube. ^ Remove the 2 transfer case vent tube bolts. 3. Remove and discard the dust shield. 4. CAUTION: The transfer case cover is aligned with the case using 2 hollow dowels. Remove the cover squarely from the dowels to avoid cracking the cover bosses. Remove the 12 transfer case cover bolts, the transfer case cover, and the gears. Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 307 P0461 Page 5189 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 7226 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 1755 Spark Plug: Application and ID Spark Plug Type Spark Plug ........................................................................................................................................... .................................................................... SP448 Page 5201 Steering Gear: Service and Repair Steering Gear Boot Steering Gear Boot Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the outer tie-rod end. 3. Remove the tie-rod end jam nut. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Remove the 2 steering gear boot clamps and the steering gear boot. 5. To install, reverse the removal procedure. Page 1823 Hose/Line HVAC: Service and Repair Compressor Manifold and Tube Assembly COMPRESSOR MANIFOLD AND TUBE ASSEMBLY Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the A/C refrigerant. 3. Remove the 2 compressor manifold and tube assembly bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the spring lock coupling from the suction accumulator. 5. Remove the front bumper cover. 6. Disconnect the condenser core peanut fitting. - Remove the condenser core peanut fitting nut. To install, tighten to 8 Nm (71 lb-in). 7. Remove the RH splash shield. 8. If equipped, disconnect the engine block heater. 9. Disconnect the A/C compressor electrical connector. 10. Remove the manifold and tube assembly bolt. - To install, tighten to 20 Nm (15 lb-ft). Connector Views Engine Control Module: Connector Views Page 1417 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Page 2198 Installation 1. NOTE: Do not reuse the crankshaft pulley bolt. NOTE: Apply clean engine oil on the seal area before installing. Install the crankshaft pulley and hand-tighten the bolt. 2. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install a standard 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover. ^ Rotate the pulley as necessary to align the bolt holes. 3. CAUTION: Failure to hold the crankshaft pulley in place while tightening the bolt can cause damage to the engine front cover. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: ^ Stage 1: Tighten to 100 Nm (74 ft. lbs.). ^ Stage 2: Tighten an additional 90 degrees (1/4 turn). 4. Remove the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt. Page 5735 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ........................................................................................................................ PAG Refrigerant Compressor Oil (R134a Systems) * Meeting Ford Specification WSH-M1C231-B Page 1103 Page 6442 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 8039 Wiper Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. P1156 P1156 Page 2403 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Page 2637 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 6511 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 1971 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Locations View 151-7 (Engine, front) Specifications Firing Order: Specifications Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 6306 Navigation System: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) Symptom Chart (Part 2) Page 3000 Powertrain Control Module (PCM) C175b Restraint Control Module (RCM) C2041a Page 1072 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). Locations View 151-10 (Automatic Transmission) Page 6447 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 Locations View 151-7 (Engine, front) Page 1842 Disclaimer Page 1129 Page 2811 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 6470 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 3280 manifold as possible. Because the light off catalyst is located close to the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights of{ the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio 14.7 pounds of air to 1 pound of fuel (14.7: 1) for high conversion efficiency. In order to achieve these high efficiencies the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency. For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NO conversion efficiency. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. 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 (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. 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 afier the light-off catalyst. Page 3455 Wheel Speed Sensor-Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor-Front Wheel Speed Sensor-Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The harness connector is located in the engine compartment. Disconnect the electrical connector. 3. Using a suitable tool, remove the grommet. 4. Remove the front wheel speed sensor wire from the retainer. 5. Remove the 2 front wheel speed sensor wire bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). Diagrams Page 3468 9. 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 vapor tube or retainer clip is broken or damaged, install a suitable fuel tube disconnect tool to separate the retainer clip legs. Once the retainer clip legs have separated, lift the clip out of the connector housing, lifting the stamped side of the connector body. Disconnect the fuel vapor tube quick connect couplings from the intake manifold and the emissions canister purge valve. Push the connector toward the tube to release the pressure. - Press the fuel vapor tube quick connect coupling button and pull the fuel vapor tube to disconnect. 10. Detach the fuel vapor tube retainers. - Remove the fuel vapor tube. 11. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating the tube. Disconnect the fuel vapor tube quick connect coupling from the evaporative emissions (EVAP) canister purge valve. 1 Press the fuel vapor tube quick connect coupling locking tabs. 2 Disconnect the fuel vapor tube quick connect coupling. 12. 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. Disconnect the fuel supply jumper tube and the fuel vapor tube quick connect couplings. 1 Press the quick connect coupling locking tabs. 2 Disconnect the fuel supply jumper tube and the fuel vapor tube quick connect couplings. 13. Release the fuel supply and fuel vapor tubes from the frame-mounted retainer clip. Page 4185 Front Drive Halfshaft Removal NOTE: RH is shown; LH is similar. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the front wheel hub nut. 3. Remove the ABS wheel speed sensor bolt and position the sensor aside. 4. Remove the lower arm pinch bolt and nut from the lower arm. 5. Separate the lower arm from the front wheel knuckle. 6. Using the special tool, separate the front drive halfshaft from the front wheel hub. Page 7705 Parking Lamp Relay: Testing and Inspection Page 7885 View 151-24 (Rear Door (RH Side Shown, LH Side Similar)) Page 7433 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 872 View 151-21 (Passenger Seat) Page 2874 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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 7030 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 935 Page 1143 Page 6392 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 Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 5185 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Page 4076 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Remove the shift cable from the gearshift assembly. 1 Disconnect the shift cable end from the gearshift lever. 2 Remove the shift cable from the bracket. Page 181 P0268 Page 7412 Page 7875 Page 1710 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Page 5936 Page 1428 Throttle Position Sensor: Diagrams Page 1105 Parking Assist Distance Sensor: Service and Repair PARKING AID SENSOR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The rear bumper cover removal is only necessary for access to the outer parking aid sensors. The inner parking aid sensors do not require rear bumper cover removal for access. Remove the rear bumper cover. 3. Press the retaining tabs and remove the parking aid sensor. - Disconnect the electrical connector. 4. To install, reverse the removal procedure. Page 7579 Page 1509 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 6462 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 865 Locations View 151-11 (Manual Transmission) Page 3281 Underbody Catalyst The underbody catalyst is located afier the light off catalyst. The underbody catalyst may be in-line with the light off catalyst or the underbody catalyst may be common to 2 light off catalysts forming a Y pipe configuration. Three-Way Catalytic Converter The 3-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 NO. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. 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. For information on the HO2S refer to PCM Inputs in this section. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Locations View 151-12 (Dash Panel) Page 4646 Brake Master Cylinder: Service and Repair Brake Master Cylinder Material Removal and Installation 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. 1. Disconnect the battery. 2. Disconnect the brake fluid level warning switch electrical connector. 3. Using a suitable suction device, remove the brake fluid from the brake master cylinder reservoir. Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal and Bracket Removal and Installation 1. Disconnect the battery. 2. Remove the brake pedal position (BPP) switch. 3. On speed-control equipped vehicles, remove the speed-control deactivator switch. 4. Remove the brake booster pushrod pin redundant clip. 5. Remove the brake pedal self-locking pin. 6. Remove the brake booster pushrod outer bushing. 7. Slide the brake booster pushrod off the brake pedal pin and position the pushrod aside. 8. Remove the brake booster pushrod inner bushing. 9. Remove the brake pedal bracket upper bolt. ^ To install, tighten to 23 Nm (17 ft. lbs.). 10. Remove the brake pedal bracket upper nut. ^ To install, tighten to 23 Nm (17 ft. lbs.). 11. Remove the 4 brake booster nuts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 12. Remove the brake pedal and bracket assembly. ^ Position the brake booster forward to allow the brake pedal and bracket assembly to clear the brake booster studs. Locations View 151-12 (Dash Panel) Description and Operation 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. The child safety seat tether anchors are attached to the roof near the rear liftgate. If the child safety seat tether anchors were in use during a collision, inspect and install new anchors as necessary. Return the vehicle structure to its original production configuration. 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. 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) welded to the 60 percent and the 40 percent rear seat backrest frame. 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, install a new seat backrest frame. Page 1355 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. Page 3890 Shift Interlock: 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 6873 Trim Panel: Service and Repair C-Pillar Trim Panel C-PILLAR TRIM PANEL Removal and Installation 1. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt D-ring cover and remove the safety belt bolt. To install, tighten to 53 Nm (39 lb-ft). 2. Remove the pin-type retainer and the rear door scuff plate trim panel. 3. Position the liftgate weatherstrip aside. 4. If equipped, remove the cargo net hold-down. 5. NOTE: Insert a tape-wrapped screwdriver between the D-pillar trim panel and rear quarter trim panel to release the trim panel. Remove the rear quarter trim panel. 6. Position the rear door weatherstrip aside. 7. Remove the cover, the bolt, and the C-pillar trim panel. - To install, tighten to 7 Nm (62 lb-in). 8. To install, reverse the removal procedure. Page 4068 Removal 1. Remove the transaxle. 2. Using the special tool, lock the flywheel to the engine. Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Page 7906 View 151-23 (Right Front Door) Page 678 P1566 P0265 P0265 Page 2050 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 6874 Trim Panel: Service and Repair Liftgate Trim Panel LIFTGATE TRIM PANEL Removal and Installation 1. Remove the 4 screws and the liftgate trim panel. 2. To install, reverse the removal procedure. Page 2364 23. Install the engine plug bolt. ^ Tighten to 20 Nm (15 ft. lbs.). 24. Install the accessory drive belt and idler pulleys. 25. Install the engine mount. 26. Install the valve cover. Page 7081 Page 4904 Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 1950 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) Special Tool(s) 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 7021 Symbols Part 3 Page 4100 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 5695 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the RH splash shield. 4. If equipped, disconnect the engine block heater electrical connector. 5. Disconnect the A/C compressor electrical connector. 6. Remove the suction accumulator to compressor line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the suction accumulator to compressor line from the A/C compressor. 8. Remove the 2 suction accumulator to compressor line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the suction accumulator to compressor line spring lock coupling. 10. Remove the suction accumulator to compressor line. 11. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 580 P1383 Page 5758 Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................. 1.25 - 1.35mm (0.049 - 0.053 in.) Spark Plug Tightening Torque ............................................................................................................. ........................................................ 12 Nm (9 lb.ft.) Page 4786 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 an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable cam timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: Eliminate cruise control actuators. - Eliminate idle air control (IAC) valve. - Better airflow range. - Packaging (no cable). - More responsive powertrain at altitude and improved shift quality. It should be noted that the ETC system includes a warning indicator (wrench light) on the instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage. - Signal return (ground). - TP1 voltage with negative voltage slope (5-0 volts). - TP2 voltage with positive voltage slope (0-5 volts). Accelerator Pedal Position (APP) Sensors Page 5905 Seat Occupant Sensor: Description and Operation OCCUPANT CLASSIFICATION SENSOR CAUTION: - It is necessary to rezero the OCS system when a front passenger seat cushion is disassembled, a new trim cover installed, or an OCS service kit is installed. A diagnostic tool is used to trigger the active command to carry out rezeroing of the OCS system. - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated seat). Always make sure the correct OCS service kit is installed. - Make sure the seat is completely assembled before rezeroing. - The following precautions must be taken before rezeroing of 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 5-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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" once rezeroing of the OCS system is complete. - 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. - To identify between a production OCS system and a OCS system service kit, inspect the OCS ECU electrical connector. A production OCS system allows the disconnect of the electrical connector from the OCS ECU. An OCS system service kit (OCS service kit) has the OCS ECU electrical connector glued to the ECU, it cannot and should not be disconnected or altered. An OCS system service kit also has an in-line 10-pin connector between the OCS ECU and the seat wiring harness. - 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. The seat occupant classification sensor system is found only on the front passenger seat. The front passenger seat occupant classification sensor (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 bladder when the 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 pressure sensor, then electronically communicated to the OCS electronic control unit. Based on programmed limits, the OCS electronic control unit will inform the restraints control module (RCM), via a High Speed Controller Area Network (CAN), of the necessary information. The RCM uses this information in determining if the passenger air bag module or passenger seat side air bag module is to be deployed in the event of a deployable collision. 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 is also used for operation of the passenger Belt Minder. To deactivate or reactivate the passenger Belt Minder feature, refer to Instrument Panel, Gauges and Warning Indicators or the owner literature. Diagrams Page 715 P1703 Page 165 P0230 - P0234: Testing and Inspection P0232 P0232 (Part 1) P0232 (Part 2) Page 3053 View 151-8 (Engine, rear) Page 7615 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 7516 A7 Normal Operation When a door or liftgate is opened, the ajar switch opens the circuit to the SJB. The SJB grounds the interior lamp 401 (PK) circuit, illuminating the interior lamps. Possible Causes - circuit 1695 (YE/WH) open - circuit 1005 (VT/OG) open or short to ground - circuit 401 (PK) open or short to voltage - SJB Test B: The Interior Lamps Stay On Continuously PINPOINT TEST B: THE INTERIOR LAMPS STAY ON CONTINUOUSLY B1-B3 P0537 P0535 - P0539: Testing and Inspection P0537 P0537 (Part 1) P0537 (Part 2) Page 7435 Symbols Part 3 Page 7265 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 3430 View 151-8 (Engine, rear) Page 5883 2. NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the C-pillar sheet metal. 3. WARNING: The tightening torque of the air bag side impact sensor retaining bolt is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 4. Install the C-pillar trim panel. 5. Repower the system. Page 7544 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 Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 7487 Symbols Part 2 Service and Repair Universal Joint: Service and Repair Driveshaft Universal Joint Disassembly and Assembly Special Tool(s) CAUTION: Do not reuse the bolts and cap straps for either the center U-joint or the rear U-joint. Install new bolts and cap straps or damage to the vehicle may occur. NOTE: There is a difference in length of the head of the replacement yoke strap bolts from the production bolts. The longer head pinion bolts can be used in either location. 1. Remove the driveshaft. 2. Clamp the special tool into a vise. 3. Remove the universal joint cap snap rings. Page 5658 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 2456 Page 4949 Fuse: Application and ID Battery Junction Box Page 2810 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 2595 Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 6129 View 151-21 (Passenger Seat) Page 933 Locations View 151-3 (Engine Compartment, 1 Of 2) Description and Operation Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 7542 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 Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand 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 IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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. Locations View 151-12 (Dash Panel) Page 2194 Flexplate, Flywheel and Crankshaft Rear Oil Seal Page 7455 Brake Lamp: Pinpoint Tests High Mounted Stoplamp C475 RH Rear Lamp C418, LH Rear Lamp C419 Page 2910 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 2922 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: Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. System Diagnosis P0581 Locations Diagrams Cargo Lamp: Diagrams Page 3880 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 7896 Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP leak check monitor. Service and Repair Intake Air Duct: Service and Repair AIR CLEANER OUTLET PIPE Page 5914 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Worldwide Diagnostic System (WDS) Special Tool(s) Page 5546 Page 5679 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 6050 Seat Belt Retractor: Service and Repair Rear Safety Belt Retractor REAR SAFETY BELT RETRACTOR Torx Bit, Safety Belt Bolt Special Tool(s) Removal and Installation WARNING: All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 Page 1164 Page 5092 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer P1260 P1260 Page 3416 Service and Repair Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 5667 Heater Core: Service and Repair HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. 1. Drain the engine coolant. 2. Release the 2 clamps and disconnect the 2 heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the screw and the temperature blend door lever. 5. Remove the 3 screws and the heater core cover. 6. Remove the heater core from the housing. 7. NOTE: - Make sure the temperature blend door actuator and switch are in the correct position when installing the temperature blend door lever. - Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. Fill and bleed the engine cooling system. Page 5960 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 4758 6. Disconnect the generator electrical connector. 7. Remove the generator lower air duct bolt. - To install, tighten to 4 Nm (35 lb-in). 8. Press the locking tab to release the generator lower air duct from the generator and remove the lower air duct. 9. Remove the pin-type retainer from the bottom of the generator shield. 10. Remove the generator shield nut and the generator shield. - To install, tighten to 20 Nm (15 lb-ft). 11. Remove the generator stud nut. - To install, tighten to 47 Nm (35 lb-ft). 12. Remove the generator stud. - To install, tighten to 24 Nm (18 lb-ft). 13. Remove the 2 generator bolts and the generator. - To install, tighten to 47 Nm (35 lb-ft). 14. To install, reverse the removal procedure. Page 7045 The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat and depower the SRS. 2. Using a small flat-blade screwdriver, release the locking tab and slide the heated seat module off the bracket. - Disconnect the electrical connector. 3. To install, reverse the removal procedure. 4. Install the front seat and repower the SRS. Page 6449 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. Locations View 151-7 (Engine, front) Page 5584 Disclaimer Service and Repair Seat Track: Service and Repair SEAT TRACK Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Page 2472 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 4236 Flexplate, Flywheel and Crankshaft Rear Oil Seal Page 7299 PINPOINT TEST C: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY C1-C2 Page 4754 Page 2665 Mechanical Returnless Fuel Pump Module (FPM) Restraints - Control Module DTCs & Associated Fault PIDs Air Bag 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. Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... .......................................................... 680 - 750 RPM Page 7692 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 7640 Smart Junction Box (SJB) C2280b Test A: The Horn Is Inoperative PINPOINT TEST A: THE HORN IS INOPERATIVE A1-A2 Page 2330 1. Install the valve stem seal installation sleeve. 2. Using the special tool, install the valve seal. 3. NOTE: Check the seating of the valve collet. Using the special tools, install the valve spring. ^ Insert the valve spring and the valve spring retainer. ^ Compress the valve spring and install the valve collet using some grease and a small screwdriver. 4. NOTE: Do not tighten the spark plug at this time. Disconnect the compressed air supply and install the spark plug. 5. Repeat the appropriate removal and installation steps for all of the other cylinders. 6. Tighten the spark plugs to 15 Nm (11 ft. lbs.). 7. Coat the valve tappets with clean engine oil and insert them. 8. Install the camshafts. Page 902 Compressor Clutch Relay: Testing and Inspection Page 4613 Brake Bleeding: Service and Repair Gravity Bleed Gravity Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RR wheel, to the LR wheel, to the RF wheel, and ending with the LF wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Loosen the bleeder screw and leave it open until clear, bubble-free brake fluid flows. 5. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 6. Continue bleeding the brake hydraulic system at each wheel. 7. Fill the brake master cylinder reservoir with the specified brake fluid. Page 7616 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 P1436 P1436 Locations View 151-12 (Dash Panel) Page 5773 Clutch Cycling Orifice Tube Type Refrigerant System (Part 2) Page 7580 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH Removal and Installation 1. NOTE: The fog lamp switch is removed by pushing from behind. Remove the fog lamp switch from the instrument panel. Disconnect the fog lamp switch electrical connector. 2. To install, reverse the removal procedure. Page 3116 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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. Catalytic Converter - Manifold Catalytic Converter: Service and Repair Catalytic Converter - Manifold Catalytic Converter-2.3L Manifold Special Tool(s) Material Page 4485 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 1028 Page 6235 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 3891 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 Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Description and Operation EGR Control Module: Description and Operation EGR SYSTEM MODULE (ESM) Overview EGR System Module (ESM) The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional DPFE system, however the various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a traditional DPFE system. The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional tests that monitor various aspects of the EGR system operation. First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405 P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403). NOTE: EGR normally has large amounts of water vapor that are the result of the engine combustion process. During cold ambient temperatures, under some circumstances, water vapor can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to prevent MIL illumination for temporary freezing, the following logic is used. If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines that the malfunction is no longer present, the EGR system will be enabled and normal system operation will be restored. If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the malfunction has been detected on 2 consecutive driving cycles. After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is evaluated to determine the amount of EGR system restriction. If the differential pressure is below a calibrated threshold, a low flow malfunction is indicated (P0401/P0406). Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero requested EGR flow to carry out the high flow check. If the differential pressure exceeds a calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR valve seat (P0402). If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles for the EGR monitor to be set to a ready condition. Page 2604 Page 3701 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 5998 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of injury in collisions. - 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 reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 driver seat safety belt buckle pretensioner is shown, the passenger side is similar. 1. Depower the SRS. 2. CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting on a seat not secured in the vehicle may result in damaged components. Remove the affected seat from the vehicle. 3. Remove the inboard seat cushion side shield. 1 Remove the front and rear side shield screws (front shown). 2 Remove the inboard seat cushion side shield. 4. Disconnect the safety belt buckle pretensioner electrical connectors. 5. NOTE: Note the wire harness routing for installation. Detach the pin-type retainers and separate the safety belt buckle and pretensioner electrical connectors and wire harness from the seat. 6. Remove the bolt and the safety belt buckle pretensioner. - To install, tighten to 40 Nm (30 lb-ft). 7. To install, reverse the removal procedure. 8. Repower the SRS. 9. Check the active restraint system for correct operation. Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 4910 Specifications Piston Ring: Specifications Rings Ring groove width - top ........................................................................................................................................... 1.203-1.205 min (0.0473-0.0474 in.) Ring groove width - 2nd .............................................................................................................................................. 1.17-1.19 min (0.0460-0.0468 in.) Ring groove width - oil ............................................................................................................................................ 2.501-2.503 min (0.0984-0.0985 in.) Width - top ................................................................................. ................................................................................ 1.17-1.185 mm (0.0460-0.0466 in.) Width - 2nd .............................................................................................................................................................. 1.197-1.199 mm (0.0471-0.0472 in.) Width - oil .................................................................................. ...................................................................................... 2.38-2.45 mm (0.093-0.096 in.) Ring gap (in bore) - top ................................................................................................................................................... 0. 16-0.31 mm (0.006-0.012 in.) Ring gap (in bore) - 2nd ................................................................................................................................................... 0.33-0.48 mm (0.012-0.018 in.) Ring gap (in bore) - oil ........................................................................................................................................................ 0.2-0.7 mm (0.007-0.027 in.) Page 7511 Liftgate Glass Ajar Switch C479 Smart Junction Box (SJB) C2280b Smart Junction Box (SJB) C2280c Page 7521 C3-C5 Normal Operation When a door or liftgate is opened, the ajar switch opens the circuit to the SJB. The SJB grounds the interior lamp 401 (PK) circuit, illuminating the interior lamps. Possible Causes - circuit 1312 (LG/BK) short to ground - circuit 867 (DB) short to ground Page 6847 Starting on either side of the vehicle, position the supplied drill guide onto the foam block so that the locating pin is set into the indentation on top of the block and the "wings" are resting on either side of the block, preventing the guide from moving side-to-side. See Figure 4. 4. WARNING: WEAR SAFETY GLASSES. CAUTION: DO NOT USE an air-powered drill for this operation. Oil spray from the tool may damage the foam block or other interior trim. CAUTION: Be sure to keep the drill motor at full speed and frequently clear the chips from the bit while drilling each hole. Bore the holes at a slow to moderate pace using light to moderate pressure on the drill. Attempting to bore the holes at a fast pace using excessive pressure on the drill, or failing to clear the chips from the bit, may cause the foam blocks to crack. NOTE: Be sure to allow the drill motor to achieve full speed before attempting to bore the hole. Drill the holes as follows: A. Holding the drilling guide securely in place, position the drill bit in either of the two (2) guide holes. See Figure 5. B. Start the drill motor and allow it to achieve full speed. Page 5916 a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connector(s) and wiring clips. 1 Disconnect the seat wire harness OCS electrical connector from the service part OCS electrical connector. 2 Release the 2 wiring clips on the wiring harness from the cushion pan. 3 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. Page 7384 Page 5867 Impact Sensor: Locations Side Impact Sensor View 151-16 (Full Body, Left Rear - 2 Of 2) Page 3024 Information Bus: Service and Repair PROGRAMMABLE MODULE INSTALLATION Worldwide Diagnostic System (WDS) Special Tool(s) Using the Vehicle Communication Module (VCM) When the Original Body Chassis Electrical Module is Not Available 1. Install the new module. 2. Using the VCM and the latest version of the service function card, SELECT: Programmable Module Installation. 3. Select the module being installed. 4. Follow the on-screen instructions. 5. SELECT: Retrieve Module Configuration - Old ECU and press trigger. 6. Follow the on-screen instructions. 7. The VCM attempts to retrieve the module data from the powertrain control module (PCM). - If the module data is available, go to Step A. - If the VCM displays: Call As-Built Data Center, go to Step B. Step A 1. SELECT: Restore Configuration - New ECU. Press trigger. 2. The VCM completes loading the retrieved data and displays Module Download Successful. 3. Test the module for correct operation. Step B 1. Press the trigger. 2. If the VCM asks for vehicle data, enter the vehicle data, then press store. 3. The VCM asks for module data line 1. Enter the data and press store. 4. The VCM then asks if there is an additional line of data available for that address. Select YES or NO depending on the information in the As Built Data Sheet. 5. Repeat Steps 3 and 4 until the answer is NO for Step 4. 6. The VCM should show a screen stating that the module data was stored. Press the trigger. 7. Follow the on-screen instructions. 8. SELECT: Restore Configuration - New ECU. Press the trigger. 9. The VCM completes loading the retrieved data and displays Module Download Successful. 10. Test the module for correct operation. Using the Vehicle Communication Module (VCM) When the Original Body Chassis Electrical Module is Available 1. With the original module still installed, using the VCM and the latest version of the service function card, SELECT: Programmable Module Installation. 2. Select the module being installed and press the trigger. 3. Follow the on-screen instructions. 4. SELECT: Retrieve Module Configuration - Old ECU. Press the trigger. 5. Follow the on-screen instructions. 6. INSTALL new module, SELECT: Restore Configuration - New ECU. Press the trigger. 7. The VCM completes loading the retrieved data and displays Module Download Successful. 8. Test the module for correct operation. Using the Worldwide Diagnostic System (WDS) When the Original Body Chassis Electrical Module is Not Available 1. Install the new module. 2. Connect the WDS and ID the vehicle as normal. 3. From the Toolbox icon, select and highlight Module Programming. Then highlight the module that was installed and press the check mark. 4. Select and highlight Programmable Module Installation. Then highlight the module that was installed and press the check mark. 5. Follow the on-screen instructions, turn the ignition key to the OFF position and press the check mark. 6. The WDS retrieves the module data from the PCM, automatically downloads the data into the new module, and displays Module Configuration Service and Repair Fog/Driving Lamp Bulb: Service and Repair FOG LAMP BULB Removal and Installation WARNING: The halogen fog lamp bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its base. Avoid touching the glass envelope. Failure to follow these instructions may result in personal injury. CAUTION: The fog lamp bulb should not be removed from the fog lamp until just before a new bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. NOTE: Make sure the headlamp switch and the ignition switch are in the OFF position. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 4 front fender splash shield bolts. - To install, tighten to 5 Nm (44 lb-in). 3. Remove the 4 front fender splash shield pin-type retainers. - Position the front fender splash shield aside. 4. Disconnect the fog lamp bulb electrical connector. 5. Rotate the fog lamp bulb counterclockwise and remove the fog lamp bulb. 6. To install, reverse the removal procedure. Page 6495 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 5103 Difference From Standard Position (RH Side) 6. Install and tighten the front strut upper mounting bracket nuts. Fuel System - Slow Fuel Fill/MIL ON/DTC P0451 Fuel Tank Vent: All Technical Service Bulletins Fuel System - Slow Fuel Fill/MIL ON/DTC P0451 TSB 08-5-5 03/17/08 SLOW FUEL FILL AND/OR DTC P0451 FORD: 2005-2008 Escape Hybrid, Escape MERCURY: 2005-2008 Mariner 2006-2008 Mariner Hybrid This article supersedes TSB 07-25-7 to update the Title and Service Procedure. ISSUE Some 2005-2008 Escape, Escape Hybrid, Mariner and 2006-2008 Mariner Hybrid vehicles may exhibit a slow fuel fill concern or a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0451 present. The condition may be caused by water/moisture or other contamination entering the fuel filler vent line and then freezing and/or causing a blockage. ACTION Follow the Service Procedure steps to correct the condition by relocating the fuel filler vent line. SERVICE PROCEDURE When performing this procedure it is not necessary to: ^ Drain any fuel from the tank ^ Remove the stone shield from the filler pipe ^ Disconnect the filler pipe from the fuel tank NOTE ANY WATER/MOISTURE OR OBSTRUCTIONS IN THE EVAPORATIVE VENT SYSTEM MUST BE REMOVED. 1. With the vehicle in neutral, position it on a hoist. 2. Remove the left rear wheel. 3. Remove the fuel filler cap. 4. Remove the two (2) upper filler pipe mounting screws. 5. Remove the single lower filler pipe mounting screw. 6. Carefully pull the upper end of the filler pipe away from the inner wheel well to gain access to the vent line. 7. Cut any tape or plastic straps holding the black plastic convoluted vent line to the filler pipe or underbody. 8. Pull the black plastic convoluted vent line underneath the vehicle. 9. Remove the vent line from the dust separator attached to the canister assembly and clear out the line using compressed air. 10. Inspect the dust separator for water/moisture or any obstruction. If water/moisture or obstructions are present follow Workshop Manual (WSM), Section 310-00 pinpoint test A. If no water/moisture or obstructions are present reattach vent line to dust separator and continue to next step. 11. Remove but do not discard the spider screen (vent cap) from the end of the vent line. 12. Measuring from the open end of the vent line, cut off and discard the last 13" (35 cm). 13. Reinstall the spider screen (vent cap) in the vent line. A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle 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 only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Page 7304 E1-E3 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - compass sensor module - vehicle is magnetized - zone setting - compass out of calibration Page 7698 Marker Lamp: Connector Views Page 2101 1. Using the special tools, install a new wheel bearing into the wheel knuckle. 2. Install the wheel bearing snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. FWD vehicles 4. Install the ABS wheel speed sensor ring. 5. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 4WD vehicles 6. Install the wheel knuckle. Page 3317 - Apply oil to the EVAP canister vent solenoid O-ring seal prior to installation. 6. To install, reverse the removal procedure. 7. Carry out the evaporative emission system leak test. See: Testing and Inspection/Evaporative Emission System Leak Test 8. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Page 1630 Page 4652 Wheel Cylinder: Service and Repair Disassembly and Assembly Wheel Cylinder Material Disassembly and Assembly 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. 1. Remove the rear wheel cylinder. 2. Remove the bleeder screw cap. 3. Remove the bleeder screw. ^ To install, tighten to 8 Nm (71 inch lbs.). 4. Remove the 2 dust boots. 5. Remove the 2 pistons. 6. Remove the 2 piston seals. ^ To install, lubricate the piston seals with clean brake fluid. 7. Remove the spring. 8. NOTE: Inspect the wheel cylinder bore for excessive wear, corrosion, or pitting. If any of these conditions exist, a new wheel cylinder must be installed. Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................... 7.6 qts. (7.2L) Page 3867 View 151-10 (Automatic Transmission) Page 2214 Valve Clearance: Service and Repair Valve Clearance Check 1. Remove the valve cover. 2. CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in these locations. Page 751 P2007 Page 617 P1461 Page 2780 Page 1453 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Page 4419 2. NOTE: Press the transfer case RH halfshaft dust shield firmly to snap it into position. Install the transfer case RH halfshaft dust shield. 3. NOTE: Clean the intermediate shaft before assembly. Use 600 grit sandpaper on the seal journals and wipe them dry. Install the front drive axle intermediate shaft. 4. Install the transfer case heat shield and the 3 transfer case heat shield bolts. ^ Tighten to 14 Nm (10 ft. lbs.). 5. Install the exhaust system crossover pipe. 6. Check the transfer case fluid level. 7. Check the transaxle fluid level. Page 1032 ^ 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 6758 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 2873 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation 1. Remove the driver air bag module. 2. Remove the 4 steering wheel cover screws and the steering wheel cover. 3. Remove the 4 steering wheel brace nuts and the steering wheel brace. - To install, tighten to 9 Nm (80 lb-in) 4. Disconnect the electrical connectors. 5. Remove the 4 speed control switch screws and the speed control switches. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. Page 4593 Drum Brake System-Exploded View Page 3976 Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the driver side splash shield. 3. Remove and discard the transmission fluid cooler line from the pump area of the case. ^ Remove the transmission fluid cooler line from the transaxle. 4. Remove the transmission fluid cooler line bracket nut. 5. Disconnect the transmission fluid cooler hose from the auxiliary cooler. 6. NOTE: Do not remove the steel line from the converter housing. Remove the transmission fluid cooler hose from the converter housing and the lower fitting of the radiator. Discard the hose. 7. Remove the 2 bolts from the lower LH side of the main control cover. Installation CAUTION: The thermal bypass valve is flow directional. The cooler bypass valve must be installed with the end cap facing up. If not installed correctly, internal damage to the transaxle will result. NOTE: The thermal cooler bypass valve cannot be successfully cleaned by back flushing, flushing or disassembly. For vehicles that are equipped with this cold weather bypass valve, a new valve should be installed whenever the transaxle is being overhauled. 1. Install the 2 studs to the lower LH side of the main control cover. ^ Tighten to 13 Nm (10 ft. lbs.). 2. Position the thermal bypass valve onto the studs and loosely install the 2 nuts. 3. Install the transmission fluid cooler line into the case fitting. ^ Tighten to 25 Nm (18 ft. lbs.). 4. Tighten the 2 cooler bypass valve retaining nuts. ^ Tighten to 11 Nm (8 ft. lbs.). 5. Install the transmission fluid cooler hose onto the converter housing tube. Pull the red clip off the constant tension clamp to activate the clamp. 6. Install the transmission fluid cooler hose onto the auxiliary fluid cooler lower fitting. Pull the red clip off the constant tension clamp to activate the Page 5500 Air Door Actuator / Motor: Service and Repair Vacuum Control Motor VACUUM CONTROL MOTOR Removal and Installation 1. Disconnect the vacuum supply hose from the vacuum control motor. Page 5833 Page 3849 2. If the vehicle is not equipped with a PTO, use the special tools to install the RH differential seal. 3. If equipped, install the PTO. 4. Install the RH halfshaft. 5. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). 6. Fill the transaxle with clean automatic transmission fluid. 7. Start the engine and run through all the gears and check fluid level. Locations View 151-7 (Engine, front) Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 4877 Page 2783 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 FRT sensor measures the temperature 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. Page 7431 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 7782 Symbols Part 4 Page 7000 Page 7003 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may result in personal injury. - The seat 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the seat control switch knob. 4. Remove the 3 screws and the outboard front seat side cushion shield. - If equipped, disconnect the heated seat switch electrical connector. - Disconnect the seat control switch electrical connector. 5. Remove the 3 seat control switch screws. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. 7. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Page 7509 Door Ajar Switch LH Front C525, RH Front C609, LH Rear C704, RH Rear C804 Interior Lamp C918 Tires - Vibration Highway at Speeds Wheels: All Technical Service Bulletins Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 7856 Page 7685 Symbols Part 2 Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Worldwide Diagnostic System (WDS) Special Tool(s) Page 4853 Page 2492 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 4197 3. Using the special tool, install the outer halfshaft end into the hub assembly. 4. Position the lower ball joint and install the lower ball joint nut. ^ To install, tighten to 103 Nm (76 ft. lbs.). 5. Install the rear wheel hub nut. ^ To install, tighten to 300 Nm (221 ft. lbs.). 6. Install the rear coil spring. 7. Fill the axle with the specified quantity of the specified lubricant. Disassembly and Assembly Halfshaft Joint Special Tool(s) Material Disassembly CAUTION: Never pick up or hold the halfshaft by only the inner or outboard CV joint. CAUTION: Handle the halfshaft by only the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. CAUTION: Do not over-angle the CV joints. CAUTION: Damage will occur to an assembled inner CV joint if it is over-plunged outward from the joint housing. CAUTION: Never use a hammer to remove or install the halfshafts. CAUTION: Never use the halfshaft assembly as a lever to position other components. Always support the free-ends of the halfshaft. CAUTION: Do not allow the boots to contact sharp edges or hot exhaust components. CAUTION: Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage. 1. Remove the halfshaft. 2. Secure the halfshaft and Constant Velocity (CV) joint in a vise using protective jaw covers. 3. Remove the 2 inner halfshaft boot clamps. 4. Slide the inner halfshaft boot off the inner CV joint housing. Page 5506 Removal and Installation 1. Remove the defroster duct. 2. Remove the 6 side register duct screws and the register duct assembly. - Separate the side register duct from the center register duct by disengaging the tab from the slot on the center register duct. 3. To install, reverse the removal procedure. Page 3127 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the clutch pedal position (CPP) switch electrical connector. 3. Rotate the CPP switch clockwise and remove the CPP switch. 4. To install, reverse the removal procedure. Page 2798 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 6486 Z1-Z2 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits 52 (YE) and 64 (DG) supply voltage to the trailer tow LH and RH stop/turn lamps respectively. Circuit 962 (BN/WH) supplies voltage to the trailer tow parking lamps. Possible Causes - circuit 64 (DG) short to voltage - circuit 52 (YE) short to voltage - circuit 962 (BN/WH) short to voltage - SJB SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Page 4123 Shifter CVT: Service and Repair Selector Lever Bezel Selector Lever Bezel Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Place the floor shift selector lever in the (D) position. Page 315 P0482 Seat Position Sensor, Driver View 151-20 (Driver Seat) Page 7627 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 3512 14. Route the shortened vent line and spider screen (vent cap) as shown in Figure 1. 15. Push the spider screen (vent cap) at least 2" (50 mm) into the open subframe and body section alignment hole. 16. Secure the vent line to the fuel tank strap with a plastic tie strap. 17. Reposition the filler pipe into its original position. 18. Install the lower filler pipe mounting screw and tighten to 89 lb-in (10 N.m). 19. Install the two (2) upper filler pipe mounting screws and tighten to 27 lb-in (3 N.m). 20. Install the fuel filler cap. 21. Reinstall the wheel and tighten to 98 lb-ft (133 N.m). 22. Lower the vehicle from the hoist. 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 080505A 2005-2008 Escape, 0.7 Hr. Escape Hybrid And Mariner, 2006-2008 Mariner Hybrid: Relocate Fuel Filler Vent Hose. Includes Time to Remove Left Rear Wheel, Fuel Cap And Partially Remove The Fuel Filler Pipe And Shield (Do Not Use With 9030A) DEALER CODING CONDITION BASIC PART NO. CODE 9A089 55 Disclaimer Front Drive Halfshaft Axle Shaft Assembly: Service and Repair Front Drive Halfshaft Halfshaft Halfshaft Special Tool(s) Page 3205 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Locations View 151-8 (Engine, rear) Locations View 151-7 (Engine, front) Page 7827 Y5-Y6 Normal Operation Voltage to the trailer tow lamps is controlled by the smart junction box (SJB). Circuits 52 (YE) and 64 (DG) supply voltage to the trailer tow LH and RH stop/turn lamps respectively. Circuit 962 (BN/WH) supplies voltage to the trailer tow parking lamps. Ground for the trailer lamps is provided on circuit 57 (BK). Possible Causes - circuit 52 (YE) open, or short to ground - circuit 57 (BK) open - circuit 64 (DG) open, or short to ground - circuit 962 (BN/WH) open - trailer - SJB Test Z: The Trailer Lamps Are On Continuously PINPOINT TEST Z: THE TRAILER LAMPS ARE ON CONTINUOUSLY Z1 Description and Operation Seat Belt Tension Sensor: Description and Operation SAFETY BELT TENSION SENSOR The safety belt tension sensor: - is part of the front outboard passenger safety belt and retractor assembly. - is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a 3-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, when the child safety seat is installed according to manufacturer instructions. 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. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Service and Repair Output Shaft: Service and Repair Stub Shaft Pilot Bearing and Seal Special Tool(s) Material Removal 1. Remove the halfshaft assembly. C110-C311 Multiple Junction Connector: Diagrams C110-C311 P1635 P1635 Page 2559 Exhaust Pipe: Service and Repair Exhaust Flexible Pipe Exhaust Flexible Pipe Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 exhaust catalytic converter nuts. ^ To install, tighten the nuts to 47 Nm (35 ft. lbs.). 3. Remove and discard the 3 exhaust flexible pipe nuts. ^ To install, tighten to 25 Nm (18 ft. lbs.). 4. Remove and discard the exhaust hanger and remove the exhaust flexible pipe. 5. To install, reverse the removal procedure. ^ Install new gaskets. Locations Page 4089 Symbols Part 2 Page 2904 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 7001 Power Seat Switch: Testing and Inspection Locations View 151-7 (Engine, front) 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 an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable cam timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: Eliminate cruise control actuators. - Eliminate idle air control (IAC) valve. - Better airflow range. - Packaging (no cable). - More responsive powertrain at altitude and improved shift quality. It should be noted that the ETC system includes a warning indicator (wrench light) on the instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage. - Signal return (ground). - TP1 voltage with negative voltage slope (5-0 volts). - TP2 voltage with positive voltage slope (0-5 volts). Accelerator Pedal Position (APP) Sensors System Diagnosis P071x Audio System - Front Door Speaker Buzzing Front Door Panel: Customer Interest Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION BASIC PART NO. CODE 78237A05 12 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 1689 Wiper Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Locations View 151-7 (Engine, front) Driver Air Bag Module Air Bag: Service and Repair Driver Air Bag Module DRIVER AIR BAG MODULE Locations View 151-20 (Driver Seat) Page 3817 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Page 1343 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 5843 2. Remove the lower LH center instrument panel finish panel. 3. Position back the carpet on the LH and RH tunnel to access the RCM. 4. Disconnect the large 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 large RCM electrical connector. 5. Disconnect the small RCM electrical connector. 6. Remove the 3 bolts and the RCM. Installation Page 2999 Instrument Cluster C220 Parking Aid Module C4014 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 electrical damage. VISUAL INSPECTION CHART Electrical Battery junction box (BJB) fuse(s): 2 (25A) - 3 (25A) - 21 (40A) - Smart junction box (SJB) fuse(s): 1 (15A) (trailer parking lamps) - 6 (15A) - 17 (15A) - SJB - Circuity - Trailer 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. - Make sure the multifunction switch is in the low beam position. 5. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or ISO 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 Body Control Systems (Multifunction Electronic Control Module). - 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. See: Symptom Related Diagnostic Procedures NOTE: When diagnosing the trailer tow lamps, begin by verifying that the vehicle lamp systems are all functioning correctly with the trailer disconnected. Page 1667 Power Window Switch: Diagrams Window Adjust Switch Page 701 P1641 Service and Repair Trunk / Liftgate Lock: Service and Repair LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 6663 5. Remove the liftgate latch remote control assembly. - Remove the screw and 2 nuts. To install, tighten the nuts to 7 Nm (62 lb-in). - To install, tighten the screw to 3 Nm (27 lb-in). 6. To install, reverse the removal procedure. - Transfer all necessary components. Page 4948 Page 1038 Starter Relay: Testing and Inspection Page 2398 Spark Plug: Application and ID Spark Plug Type Spark Plug ........................................................................................................................................... .................................................................... SP448 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 2576 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts). - 2 signal return (ground) circuits. - APP1 voltage with negative voltage slope (5-0 volts). - APP2 voltage with positive voltage slope (0-5 volts). - APP3 voltage with positive voltage slope (0-5 volts). 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a fault. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value will be substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Page 5707 - Evacuate, leak test, and charge the refrigerant system. Evaporator Inlet Line EVAPORATOR INLET LINE Removal and Installation 1. Recover the refrigerant. 2. Loosen the nuts and disconnect the evaporator inlet line fittings. - Remove and discard the O-rings. - To install, tighten to 10 Nm (89 lb-in). 3. Remove the evaporator inlet line. 4. NOTE: New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Charge and leak test the refrigerant system. Evaporator Inlet Line - Orifice Tube EVAPORATOR INLET LINE - ORIFICE TUBE Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Drivetrain - Fluid leak From PTU Vent Case: All Technical Service Bulletins Drivetrain - Fluid leak From PTU Vent TSB 09-4-4 03/09/09 PTU VENT BOLT LEAK - MISDIAGNOSED AS PTU SHAFT SEAL LEAK FORD: 2005-2009 Escape Hybrid, Escape MERCURY: 2005-2009 Mariner 2006-2009 Mariner Hybrid ISSUE Some 2005-2009 Escape, Mariner, Escape Hybrid and 2006-2009 Mariner Hybrid vehicles may exhibit a leak from the power transfer unit (PTU) vent tube bolt. This may be misdiagnosed as a PTU link shaft seal leak. Please verify leak origin and tighten PTU vent tube bolt, before replacing parts. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove the PTU fill plug and check fluid level per Workshop Manual (WSM), Section 308-07B. NOTE THE FLUID LEVEL MUST BE EVEN WITH THE BOTTOM OF THE FILLER HOLE WITH THE VEHICLE ON FLAT, LEVEL GROUND. 2. Inspect PTU vent tube bolt for leak. (Figure 1) a. If PTU vent tube bolt leaking - clean bolt contact sur[aces and torque bolt to 120 +/- 19 lb-in (13.5 +/- 2.1 N.m). b. If PTU vent tube bolt not leaking - continue with normal WSM, Section 308-07B diagnosis. NOTE THIS BOLT DOES NOT REQUIRE A WASHER FOR THIS APPLICATION. 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. Service and Repair Pinion Flange: Service and Repair Drive Pinion Flange Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. Page 3970 Transmission Cooler: Component Tests and General Diagnostics Transaxle Cooling Transaxle Cooling CAUTION: Whenever the transaxle has been disassembled to install new parts a new transmission fluid cooler should be installed and the fluid cooler lines should be flushed. NOTE: Cleaning and backflushing the transmission fluid cooling system as outlined will keep contamination from reentering the transaxle and causing a repeat repair. When internal wear or damage has occurred in the transaxle, metal particles, clutch plate material may have been carried into torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transaxle troubles and must be removed from the system before the transaxle is put back in use. Transmission Fluid Cooler Transmission Fluid Cooler CAUTION: Whenever a transaxle has been disassembled to install new parts or because the valve body sticks from foreign material, the torque converter and transmission fluid cooler must be cleaned by using a suitable cleaner. Under no circumstances should an attempt be made to clean converters by hand agitation with solvent. When internal wear or damage has occurred in the transaxle, metal particles, clutch plate material or band material can be carried into the torque converter and transmission fluid cooler. These contaminants are a major cause of recurring transaxle concerns and must be removed from the system before the transaxle is returned for repair. Transmission Fluid Cooler Flow Test NOTE: The transaxle linkage adjustment, fluid level and line pressure must be within specification before carrying out this test. For transmission fluid level checking procedures, refer to Preliminary Inspection. For transaxle line pressure testing, refer to Special Testing Procedures. 1. Check the transmission fluid level and fill as necessary. 2. Remove the transmission fluid level indicator from fluid filler tube and install funnel in fluid filler tube. 3. With the vehicle in NEUTRAL, position it on a hoist. Inspect the transmission fluid cooler lines for damage. Install new transmission fluid cooler lines as needed. 4. Disconnect cooler return line (rear line) by separating the tubing from the cooler line rubber hose. 5. Plug the cooler line to avoid transmission fluid loss. 6. Connect one end of a hose to the cooler return line hose and route the other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube. 7. Start the engine and run at idle with transaxle in NEUTRAL range until the automatic transmission fluid is warm. Temperature is important to the flow rate measurement. Carry out the Fluid Cooler Flow Test. ^ Option 1: Once fluid flow no longer has air bubbles in it, remove the rubber hose from the funnel and insert it into liter container. After 15 seconds, install the hose into the funnel and measure the amount of automatic transmission fluid in the container. The rate of flow should be approximately 28 - 34 oz. (0.83 - 1.0 liter) in 15 seconds. ^ Option 2: Once fluid flow no longer has air bubbles in it, remove the rubber hose from the funnel and insert it into a liter container. As soon as one liter (1.06 quart) is dispensed into the container, install the hose into the funnel. One liter of automatic transmission fluid should flow through the cooling system in approximately 15-17 seconds. 8. Once adequate flow is determined, shut off the engine, remove the extension hose and reassemble the cooler line with the constant tension clamp. 9. If flow is inadequate, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter-out line. If flow is now liberal, carry out backflushing and cleaning procedure. Refer to Transmission Fluid Cooler Backflushing and Cleaning. Refer to transaxle fluid cooler diagnosis in Transmission Fluid Cooler. If flow is still not liberal, repair the pump or converter. 10. Check the transmission fluid level and adjust as required. Page 7015 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 7484 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 3656 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Testing and Inspection Micro ISO Relay: Testing and Inspection Page 2001 Page 5054 Page 3435 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 4925 Page 1984 Climate Control Assembly Control Assembly: Service and Repair Climate Control Assembly CLIMATE CONTROL ASSEMBLY Removal and Installation 1. Remove the instrument panel center finish panel. 2. Remove the 4 screws and the climate control assembly. 3. To install, reverse the removal procedure. Locations Page 2369 Variable Valve Timing Actuator: Description and Operation VARIABLE CAM TIMING (VCT) SYSTEM Overview The VCT enables rotation of the camshaft(s) relative to the crankshaft rotation as a function of engine operating conditions. There are 4 types of VCT systems. Exhaust Phase Shifting (EPS) system - the exhaust cam is the active cam being retarded. - Intake Phase Shifting (IPS) system - the intake cam is the active cam being advanced. - Dual Equal Phase Shifting (DEPS) system - both intake and exhaust cams are phase shifted and equally advanced or retarded. - Dual Independent Phase Shifting (DIPS) system - where both the intake and exhaust cams are shifted independently. All systems have 4 operational modes: idle, part throttle, wide open throttle, and default mode. At idle and low engine speeds with closed throttle, the PCM determines the phase angle based on air flow, engine oil temperature and engine coolant temperature. At part and wide open throttle the PCM determines the phase angle based on engine RPM, load, and throttle position. VCT systems provide reduced emissions and enhanced engine power, fuel economy and idle quality. IPS systems also have the added benefit of improved torque. In addition, some VCT system applications can eliminate the need for an external exhaust gas recirculation (EGR) system. The elimination of the EGR system is accomplished by controlling the overlap time between the intake valve opening and exhaust valve closing. Currently, both the IPS and DEPS systems are used. Variable Cam Timing (VCT) System Variable Cam Timing System The VCT system consists of an electric hydraulic positioning control solenoid, a camshaft position (CMP) sensor, and a trigger wheel. The CMP trigger wheel has a number of equally spaced teeth equal to the number (n) of cylinders on a bank plus one extra tooth (n+1). Four cylinder and V8 engines use a CMP 4+1 tooth trigger wheel. V6 engines use a CMP 3+1 tooth trigger wheel. The extra tooth placed between the equally spaced teeth represents the CMP signal for that bank. A crankshaft position sensor (CKP) provides the PCM with crankshaft positioning information in 10 degree increments. 1. The PCM receives input signals from the intake air temperature (IAT) sensor, engine coolant temperature (ECT) sensor, engine oil temperature (EOT) sensor, CMP, throttle position (TP) sensor, mass air flow (MAF) sensor, and CKP to determine the operating conditions of the engine. At idle and low engine speeds with closed throttle, the PCM controls the camshaft position based on ECT, EOT, IAT, and MAF. During part and wide open throttle, the camshaft position is determined by engine RPM, load and throttle position. The VCT system 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 cycle. The PCM calculates and determines the desired camshaft position. It will continually update the VCT solenoid duty cycle until the desired position is achieved. A difference between the desired and actual camshaft position represents a position error in the PCM VCT control loop. The PCM Page 7553 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. 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 Fully apply the brake. 4 Release the parking brake. 5 Place the transmission in DRIVE. 6 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. - Place the headlamp switch in the parking lamps ON position. If the parking lamps do not operate correctly, refer to Parking Lamp. - If the parking lamps operate correctly, go to the next step. 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. Refer to Body Control Systems (Multifunction Electronic Control Module). Test the system for normal operation. - If the high beams do not operate correctly, refer to Headlamp for correct diagnosis. Page 5046 Page 4067 Pressure Plate: Service and Repair Clutch Disc and Pressure Plate Special Tool(s) Page 4161 6. Using the special tool, remove the seal. Installation 1. NOTE: Make sure that the mating surface is clean before installing the new seal. Using the special tool, install the seal. 2. NOTE: Lubricate the pinion flange with premium long-life grease. Line up the index marks and position the pinion flange. 3. Using the special tool, install the pinion nut. ^ Tighten to 244 Nm (180 ft. lbs.). Page 2522 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. Page 4645 Brake Master Cylinder: Testing and Inspection Compensator Port Check Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to: ^ Supply additional brake fluid from the brake master cylinder reservoir needed by the brake system due to brake lining wear. ^ Allow brake fluid to return to the brake master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight turbulence in the brake master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. If clogged compensator ports are suspected, proceed as follows: 1. With the vehicle in NEUTRAL, position it on a hoist. 2. With the brakes released, attempt to rotate each wheel. If an excessive amount of brake drag exists, continue with the test. If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized brake disc caliper, brake wheel cylinder, or parking brake component. Repair or install new components as necessary. 3. Check the brake stoplamp switch adjustment and the brake pedal free play to verify that the brake pedal is not partially applied. 4. Loosen the nuts attaching the brake master cylinder to the power brake booster and pull the brake master cylinder away from the power brake booster. 5. Repeat Steps 1 and 2. If the brake drag disappears, the power brake booster is binding and a new one must be installed. If the brake drag continues, the brake master cylinder is binding and a new one must be installed. Page 3017 H8-H10 Page 1017 Page 139 P0197 Page 7238 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 1668 Service and Repair High Pressure Sensor / Switch: Service and Repair HIGH PRESSURE CUTOFF SWITCH Removal and Installation 1. Disconnect the high pressure cut-off switch electrical connector. 2. Remove the high pressure cut-off switch. 3. NOTE: A new O-ring seal lubricated with clean mineral oil must be installed before installing a new switch. To install, reverse the removal procedure. Page 2975 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 7699 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 4624 6. CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the piston. NOTE: Inspect the brake caliper piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new caliper must be installed. Remove the brake caliper piston. 1. Place a block of wood between the brake caliper piston and the brake caliper housing. 2. Apply compressed air through the brake caliper jounce hose port to remove the piston. 7. Remove the dust boot. 8. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. Remove the piston seal using a plastic or wooden tool. 9. To assemble, reverse the disassembly procedure. ^ Lubricate the piston seal with clean brake fluid. Description and Operation Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Overview The catalytic converter and exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen carbon dioxide (C02) and water vapor (H20). However~ it also contains carbon monoxide (CO) oxides of nitrogen (NO) hydrogen (H) and various unburned hydrocarbons (HCs). CO NO 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. For information on the OBD catalyst monitor refer to the description for the Catalyst Efficiency Monitor in this section. The number of HO2S used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV ULEV PZEV). On most vehicles only 2 HO2S are used in an exhaust stream. The front sensors (HO2S1 1/H02S21) before the catalyst will be used for primary fuel control while the ones afier the catalyst (H02S12/H02S22) will be used to monitor catalyst efficiency. However some partial zero emission vehicles (PZEV) will use 3 HO2S sensors for each engine bank. The stream 1 sensors (HO2S1 1/H02S21) located before the catalyst are used for primary fuel control the stream 2 sensors (H02S12/H02S22) are used to monitor the light-off catalyst and the stream 3 sensors (H02S13/H02S23) located afier the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore afi oxygen sensor control). Current PZEV vehicles use only a 4-cylinder engine so only the Bank 1 HO2S will be used. 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 246°C to 301°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust Page 1197 Engine Temperature Sensor: Service and Repair CYLINDER HEAD TEMPERATURE (CHT) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Detach the cylinder head temperature (CHT) sensor cover and position aside. 3. Disconnect the CHT electrical connector. 4. Remove and discard the CHT. - To install, tighten to 12 Nm (9 lb-ft). 5. To install, reverse the removal procedure. P1565 P1565 - P1569: Testing and Inspection P1565 P1565 (Part 1) P1565 (Part 2) Page 6588 Front Door Window Glass: Service and Repair Glass, Frames and Mechanisms - Exploded View FRONT DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 2982 Symbols Part 5 Service and Repair Keyless Entry Transmitter: Service and Repair REMOTE TRANSMITTER PROGRAMMING CAUTION: All remote keyless entry (RKE) transmitters must be programmed at the same time. 1. The vehicle must be electronically unlocked before entering program mode (via the RKE transmitter or the door lock control switch while the driver door is open). 2. Turn the ignition switch 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 locks and then unlocks all doors. 3. Within 20 seconds, press any button on a RKE transmitter; and the doors lock and then unlock to confirm that each remote transmitter has been programmed. Repeat this step for each RKE transmitter. 4. If the door locks do not respond for any RKE 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 RKE transmitters are attempted to be programmed. See: Body and Frame/Locks/Power Locks/Testing and Inspection/Initial Inspection and Diagnostic Overview/Inspection and Verification 5. Exiting the programming mode is accomplished if 1 of the following occurs: - The key transitions to the OFF position. - 20 seconds have passed since entering programming mode or since the last RKE transmitter was programmed. - The maximum number of RKE transmitters have been programmed. Page 2098 Wheel Bearing: Service and Repair Rear Wheel Bearing Page 6083 Seat Sensor/Switch: Service and Repair SEAT POSITION SENSOR Removal and Installation 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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 seat must be in rearward position. 1. Depower the system. 2. Disconnect the seat position sensor electrical connector. 3. Remove the screw and the seat position sensor. 4. To install, reverse the removal procedure. 5. Repower the system. Connector Views Page 6865 4. Push the headliner back into its proper position. Clamp in place using a flat piece of metal or wood to keep the headliner flush against the underside of the roof panel (Figure 3). Allow the adhesive to cure for 45 minutes. 5. Remove clamps and reinstall the perimeter seal. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050803A 2004-2005 Escape/Escape 0.3 Hr. Hybrid/Mariner Adhere The Headliner To The Underside Of The Roof Panel (Do Not Use With 51916A, 51916B, 51916BXH) DEALER CODING CONDITION BASIC PART NO. CODE 7851944 34 Disclaimer Page 4324 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 1155 Seat Heater Switch: Service and Repair HEATED SEAT SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the outboard front seat side cushion shield. - If removing the outboard passenger seat side cushion shield, remove the 2 screws and slide the shield forward. Disconnect the heated seat switch electrical connector. - If removing the driver seat side cushion shield, remove the 3 screws. Disconnect the heated seat switch electrical connector. - If equipped, disconnect the seat control switch electrical connector. 4. Remove the heated seat switch. 5. To install, reverse the removal procedure. 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) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Specifications Drive Pulley: Specifications Coolant pump pulley bolts ................................................................................................................... ..................................................... 25 Nm (18 ft. lbs.) P0141 P0141 Output Shaft Speed (OSS) Sensor Page 6307 Navigation System: Pinpoint Tests Anti-Lock Brake System (ABS) Module C1462 Audio Control Protocol (ACP) Module C2294a Page 6765 3. Remove the 4 bolts and position the 4 rear control arms aside. 4. Remove and discard the exhaust hanger from the subframe. 5. With an assistant, remove the 4 bolts and the rear subframe. Installation All vehicles 1. With an assistant, position the rear subframe and install the bolts. - To install, tighten to 115 Nm (85 lb-ft). 2. Install a new exhaust hanger on the subframe. 3. NOTE: The vehicle must be at ride height before tightening the bolts. Position the 4 rear control arms into the subframe. Loosely install the bolts. Vehicles with 4WD 4. Install the rear axle assembly. All vehicles 5. Tighten the 4 rear control arms bolts. - Tighten to 115 Nm (85 lb-ft). Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP leak check monitor. Transmission Range (TR) Sensor View 151-10 (Automatic Transmission) Page 1452 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 6949 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. Page 7348 Oil Pressure Sender: Service and Repair Oil Pressure Sender Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Disconnect the oil pressure sender electrical connector. 4. Remove the oil pressure sender. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. To install, reverse the removal procedure. ^ Apply pipe sealant with Teflon to the oil pressure sender threads. Page 5005 Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 7899 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: - The LH front window control switch is shown, all others are similar. - The removal and installation procedures for all window control switches are similar. 1. Remove the front door trim panel or the rear door trim panel. 2. Release the window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Adjustments Shift Cable: Adjustments Selector Lever Cable Adjustment 1. Place the floor shift selector lever in the (D) position. 2. Loosen the bolt for the Z-bracket and rotate the Z-bracket counterclockwise to allow access to the shift cable bracket. 3. Loosen the gearshift cable adjuster to adjust the cable by turning it 1⁄4 turn counterclockwise. 4. Place the transmission manual control lever in the DRIVE position. Page 7459 K2-K5 Page 3253 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 2197 7. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. Install the special tool. 8. Install the special tools. 9. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine. CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley it must be installed back onto the crankshaft. Remove the crankshaft pulley. ^ Remove the crankshaft pulley bolt and washer. ^ Remove the crankshaft pulley. Locations View 151-8 (Engine, rear) Page 6988 9. NOTE: This step is critical so that during installation the inboard and outboard tracks can be checked to make sure they are in alignment with each other. Mark the position of the outboard track C-channel to the plastic coated slide as shown. 10. NOTE: This step is critical so that during installation the inboard and outboard tracks can be checked to make sure they are in alignment with each other. Mark the position of the inboard track C-channel to the plastic coated slide as shown. 11. CAUTION: - The splines on the stud are very shallow. Do not use excessive force while turning the nut. - If the stud turns free from the seat track while removing the nut, a new seat track must be installed. Remove the seat position sensor bracket nut. Page 5468 Wheel Bearing: Testing and Inspection Wheel Bearing Inspection 1. With the vehicle in NEUTRAL, position it on a hoist. 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 bearing must be installed. Page 3925 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Disconnect the overdrive cancel switch electrical connector. 6. Remove the set screw. Locations View 151-7 (Engine, front) Page 4717 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Front Wheel Speed Sensor Ring-Front Removal and Installation 1. The front wheel speed sensor ring is integral to the front halfshaft and cannot be repaired separately. Page 6403 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 6214 Page 6967 Symbols Part 3 Page 7633 44-2 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 263 P0401 Service and Repair Drive Belt: Service and Repair Accessory Drive Belt Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. To install, reverse the removal procedure. Page 2540 manifold as possible. Because the light off catalyst is located close to the exhaust manifold it will light off faster and reduce emissions quicker than the catalyst located under the body. Once the catalyst lights of{ the catalyst will quickly reach the maximum conversion efficiency for that catalyst. Three-Way Catalyst (TWC) Conversion Efficiency A TWC requires a stoichiometric fuel ratio 14.7 pounds of air to 1 pound of fuel (14.7: 1) for high conversion efficiency. In order to achieve these high efficiencies the air/fuel ratio must be tightly controlled with a narrow window of stoichiometry. Deviations outside of this window will greatly decrease the conversion efficiency. For example a rich mixture will decrease the HC and CO conversion efficiency while a lean mixture will decreases the NO conversion efficiency. Exhaust System The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the catalytic converter through the front exhaust pipe. 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 (NO) in the exhaust emissions to an acceptable level. The reduced exhaust emissions are directed from the catalytic converter past another HO2S mounted in the rear exhaust pipe and then on into the muffler. Finally the exhaust emissions are directed to the atmosphere through an exhaust tailpipe. 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 afier the light-off catalyst. Page 6319 G3-G4 Normal Operation The audio unit receives input signals through the medium speed CAN and the audio control protocol (ACP) module. The navigation system then computes and displays the high energy power flow and miles per gallon data when selected. Possible Causes - circuit 570 (BK/WH) open - circuit 137 (YE/BK) open - circuit 833 (TN) open - circuit 856 (VT) open - circuit 1068 (LG/BK) open - ACP module - medium speed CAN Description and Operation Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. Page 2275 Oil Filter Adapter: Service and Repair Oil Filter Adapter Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Drain the engine cooling system. 4. Disconnect the 2 coolant hoses from the oil cooler. 5. Disconnect the oil pressure sender electrical connector. 6. NOTE: Discard the gasket. Remove the 4 bolts and the oil filter adapter. ^ To install, tighten to 25 Nm (18 ft. lbs.). 7. To install, reverse the removal procedure. 8. Fill and bleed the engine cooling system. Page 7436 Symbols Part 4 Page 7890 Page 397 P0707 Page 7302 D1-D3 Page 1033 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 1985 Fuse: Application and ID Battery Junction Box Service and Repair Engine Mount: Service and Repair Engine Mount Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the engine coolant degas bottle. 3. Install the special tool. 4. Remove the engine mount bracket bolt. ^ To install, tighten to 90 Nm (66 ft. lbs.). Testing and Inspection Ignition Relay: Testing and Inspection Page 4763 Page 5313 Front Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 7746 Page 7785 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 7460 K5-K7 Page 5024 Page 2100 4. Using the special tools, remove the wheel hub. 5. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 6. Remove the wheel bearing snap ring from the wheel knuckle. FWD vehicles 7. Using the special tools, remove the wheel bearing from the wheel knuckle. 4WD vehicles 8. Using the special tools, press the wheel bearing race from the wheel knuckle. Installation All vehicles Page 3950 12650D) 070506A 2005-2008 Escape/Mariner 5.8 Hrs. 4X4 2.3L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) 070506A 2005-2008 Escape/Mariner 5.9 Hrs. 4X2 3.0L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) 070506A 2005-2008 Escape/Mariner 7.5 Hrs. 4X4 3.0L: Diagnose And Replace The Torque Converter, Includes Time To Remove And Install Transmission, Backflush The Cooler System (Do Not Use With 7000A, 7000A11, 7000A12, 12650D) DEALER CODING CONDITION BASIC PART NO. CODE 7902 30 Disclaimer Page 7967 10. Using the special tool, distance the windshield glass from the body. 11. Using the special tool, cut the remaining urethane adhesive and remove the windshield glass. 12. Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld. Installation CAUTION: - After installing the urethane installed glass, the vehicle should not be driven until the urethane adhesive has cured. The curing times 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 temperatures and humidity vary). Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane bond. - Open the windows to prevent the windshield glass from being pushed out by air pressure if the doors are closed. 1. Dry fit the windshield glass, making alignment marks with tape or a non-staining grease pencil. 2. CAUTION: Do not scratch the pinch weld area. Trim the remaining urethane adhesive on the pinch weld to within the specification. The existing urethane adhesive surface should be smooth and free of cuts and contamination. 3. Use a wool applicator to apply metal primer to any exposed metal on the pinch weld. Allow 6 to 10 minutes to dry. 4. If reinstalling the original windshield glass, remove the excess urethane adhesive and the windshield moulding. 5. Clean the inside of the windshield glass surface with an alcohol-free cleaner making sure the ceramic-coated area is clean. 6. CAUTION: Wipe off the glass prep immediately after each application because it flash dries. If installing a new windshield glass, apply glass prep twice around the glass surface to be urethaned. 7. If installing a new windshield, apply glass primer to the same area that was prepped in the pervious step. Allow 5 minutes to dry. Page 3143 Engine Temperature Sensor: Description and Operation CYLINDER HEAD TEMPERATURE (CHT) SENSOR Typical Cylinder Head Temperature (CHT) Sensor The CHT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 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. 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 6393 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, Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR Removal and Installation 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Using the window control switch, lower the rear door window glass to gain access to the rear door window glass screws. 6. Disconnect the window control switch electrical connector. 7. Remove the 2 rear door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 8. Support the rear door window glass in the full up position. 9. Disconnect the rear door window motor electrical connector. 10. Remove the 3 rear door window regulator and motor bolts. - To install, tighten to 6 Nm (53 lb-in). 11. Remove the 2 nuts and the rear door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 12. To install, reverse the removal procedure. Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 923 Page 5364 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 1209 Brake Switch (Cruise Control): Description and Operation Brake Pedal Switch (BPS)/Brake Deactivator Switch BRAKE PEDAL SWITCH (BPS)/BRAKE DEACTIVATOR SWITCH The BPS, also sometimes called the brake deactivator switch, is for vehicle speed control deactivation. A normally closed switch supplies battery positive voltage (B+) to the PCM when the brake pedal is NOT applied. When the brake pedal is applied, the normally closed switch opens and power is removed from the PCM. On some applications the normally closed BPS, along with the normally open 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 7291 Driver/Vehicle Information Display: Symptom Related Diagnostic Procedures Symptom Chart (Part 1) A/T - Shifter Release Button Cap Falls Off Shifter A/T: All Technical Service Bulletins A/T - Shifter Release Button Cap Falls Off TSB 05-4-5 03/07/05 SHIFTER RELEASE BUTTON CAP FALLS OFF FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Mariner and Escape Hybrid vehicles may exhibit a loose gear selector button cap. The button cap may fall off, and will not stay in place when re-seated. ACTION Replace the gear selector button cap only, it is not necessary to replace the entire gear selector lever. For additional information, see the latest Escape/Mariner Workshop Manual CD, Section 307-05 Selector Lever Button. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 050405A 2005 Escape/Escape 0.2 Hr. Hybrid/Mariner: Replace Shifter Button DEALER CODING CONDITION BASIC PART NO. CODE 7C488 33 Disclaimer 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 1326 Air Flow Meter/Sensor: Diagrams Specifications Idle Speed: Specifications Hot Idle Speed ..................................................................................................................................... .......................................................... 680 - 750 RPM 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 in) can be added to the belt length by using a safety belt extension. Safety belt extensions are available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt extensions are only available with black webbing. 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 an extension to change the fit of the shoulder belt across the torso. Page 5596 Page 4907 Locations Cabin Air Filter: Locations CABIN AIR FILTER Removal and Installation 1. Remove the RH cowl panel grille. 2. Remove the 2 water shield screws and the water shield. 3. Remove the cabin air filter. 4. To install, reverse the removal procedure. Service and Repair Evaporative Emission Control Canister: Service and Repair EVAPORATIVE EMISSION CANISTER Removal and Installation 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. Page 1879 Fluid - A/T: Testing and Inspection Transmission Fluid Level Check Check Fluid Level and Condition CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and the outside temperature is above 10°C (50°F). NOTE: Automatic transmission fluid expands when warmed. If your vehicle has been operated for an extended period at high speeds, in city traffic, during hot weather, or while pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. The transmission fluid level should be checked at normal operating temperatures, 66°C - 77°C (150°F - 170°F), on a level surface. You can check the fluid level without driving if the outside temperature is above 10°C (50°F). When the vehicle has not been driven, and the outside temperature is above 10°C (50°F), the fluid level should be between the holes on the indicator. If the transmission fluid is to be checked when the fluid is at room temperature, the fluid level indicator could indicate that fluid should be added if the indicator is misread. If fluid is added at this time, an overfill condition could result when the vehicle reaches operating temperature of 66°C 77°C (150°F - 170°F). Fluid Level Check 1. Park the vehicle on a level surface and engage the parking brake. 2. With your foot on the brake, start the engine and move the range selector lever through all the gear ranges. Allow sufficient time for each gear to engage. 3. Place the range selector in PARK (P) and leave the engine running. 4. Remove the fluid level indicator and wipe it clean with a clean cloth. 5. Install the fluid level indicator, making sure that it is fully seated in the filler tube. 6. Remove the fluid level indicator. The fluid should be in the designated areas for normal and room temperature. High Fluid Level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift or engagement concerns and possible damage. High fluid levels can be caused by an overheating condition. 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 transmission malfunction and/or damage. If an overfill reading is indicated drain and refill the transmission. Low Fluid Level Do not drive the vehicle if the fluid level is below the hole at the bottom of the fluid level indicator, or not on the fluid level indicator and the outside temperatures are above 10°C (50°F). A low fluid level could result in poor transmission engagement, slipping, malfunction and/or damage. This could also indicate a leak in one of the transmission seals or gaskets. Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 4964 Page 6699 Front Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing clearance ................................................................................................................................ ................................ 0.027-0.052 (0.001-0.002 in.) Bearing thickness ......................................................................................................................................................... 1.496-1.520 mm (0.058-0.059 in.) Page 3173 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 1804 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 7228 Symbols Part 3 Page 4077 6. Remove the 2 nuts for the shift cable. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Loosen the bolt for the Z-bracket and rotate the Z-bracket counterclockwise to allow access to the shift cable bracket. ^ To install, tighten to 9 Nm (80 inch lbs.). 8. Disconnect the shift cable end from the manual lever. 9. Remove the shift cable from the shift cable bracket. P0010 P0010 Page 7518 B5-B7 Left Front View 151-22 (Left Front Door) Page 1253 P1500 P1500 - P1504: Testing and Inspection P1500 P1500 (Part 1) P1500 (Part 2) Description and Operation Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp (MIL) The MIL notifies the driver that the powertrain control module (PCM) has detected an OBD emission-related component or system fault. When this occurs an OBD diagnostic trouble code (DTC) will be set. ^ The MW is located in the instrument cluster and is labeled CHECK ENGINE SERVICE ENGINE SOON or the ISO standard engine symbol. ^ The MIL is illuminated during the instrument cluster prove out for approximately 4 seconds. ^ For applications with a dedicated hard wire MIL circuit the PCM will illuminate the MIL until a profile ignition pickup (PIP) signal is detected. For 2OO5 the following vehicles use a hard wire circuit: Crown Victoria/Grand Marquis Explorer Sport Trac and Ranger. ^ The MIL will remain illuminated after instrument cluster prove out if: ^ an emission related concern and DTC exists. ^ no PIP signal is detected (applications with a dedicated hard-wire MIL circuit). The PIP signal is generated in the PCM using the crankshafi position (CKP) sensor. For these applications the MIL can be helpful in diagnosing a no start. ^ the PCM does not send a control message to the instrument cluster (applications with the MIL controlled through the communication link). ^ the PCM is operating in the Hardware Limited Operation Strategy (KLOS). ^ the MIL circuit is shorted to ground (applications with a dedicated hard wire MIL circuit). ^ The MIL remains off during the instrument cluster prove out if: ^ an indicator or instrument cluster concern is present. ^ the MIL circuit is open (applications with a dedicated hard wire MIL circuit). ^ To turn off the MIL afier a repair a reset command from the diagnostic tool must be sent or 3 consecutive drive cycles must be completed without a fault. ^ For all MIL concerns go to Symptom Charts. ^ If the MIL flashes at a steady rate a severe misfire condition may exist. ^ If the MIL flashes erratically the PCM can reset while cranking if the battery voltage is low. Page 3121 Camshaft Position Sensor: Diagrams Page 7997 Windshield Washer Pump: Service and Repair Windshield Washer Pump and Reservoir WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. Disconnect the windshield and rear window washer pump electrical connectors. 4. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Disconnect the front and rear washer pump hoses. 5. Remove the 2 windshield washer reservoir bolts and the windshield washer reservoir. - To install, tighten to 6 Nm (53 lb-in). 6. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: Do not operate the windshield or rear window washer pumps prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. System Diagnosis P020x Page 7865 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. Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Page 7366 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 6961 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 4845 Page 3097 Page 6960 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 1339 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the clutch pedal position (CPP) switch electrical connector. 3. Rotate the CPP switch clockwise and remove the CPP switch. 4. To install, reverse the removal procedure. Windshield Wiper Motor View 151-3 (Engine Compartment, 1 Of 2) Page 3668 Page 5081 3. Complete worksheet as needed (Figure 5). GENERAL FRONT SUSPENSION UPPER STRUT MOUNT ADJUSTMENT INFORMATION: Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 3941 10. To install, reverse the removal procedure. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. ^ Adjust the shift cable after installation. Page 1964 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 6971 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 4807 Fuse: Application and ID Battery Junction Box Page 9 P0011 Page 5380 1. WARNING: Always wear safety goggles when using a spring compressor. Failure to follow these instructions may result in personal injury. NOTE: Do not use an impact wrench on the nut. Mount the strut and spring assembly in a suitable spring compressor. 2. Compress the coil spring enough to relieve the tension on the strut assembly. 3. Remove the strut piston rod-to-bushing nut. ^ To assemble, tighten to 103 Nm (76 ft. lbs.). 4. Remove the strut. 5. Remove the lower coil spring insulator. 6. Remove the coil spring. 7. Remove the upper coil spring insulator. 8. NOTE: During assembly, assemble the bearing plate to the strut so the arrow on the bearing plate points to the outboard side of the vehicle when the strut is installed. Remove the bearing plate. 9. Remove the bearing. 10. Remove the strut upper bushing. 11. Remove the dust boot and the bumper. 12. To assemble, reverse the disassembly procedure. Page 1815 Heater Hose To Oil Cooler Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the engine coolant. 3. If removing the heater core hoses, remove the heater hose tie. 4. Release the clamps and remove the necessary heater hose(s). 5. To install, reverse the removal procedure. NOTE: Lubricate the coolant hoses with plain water only if needed. Fill the engine cooling system. Page 243 P0351 Description and Operation Fuel Pressure Pulsation Damper: Description and Operation FUEL RAIL PULSE DAMPER The fuel rail pulse damper is located on the fuel rail and reduces the fuel system noise caused by the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold vacuum to avoid fuel spillage if the pulse damper diaphragm ruptures. (The fuel rail pulse damper should not be confused with a fuel pressure regulator; it does not regulate the fuel rail pressure.) Page 7323 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 6138 6. 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. Detach the seat cushion trim cover J-clips from the seat cushion pan and remove the seat cushion trim cover. 7. Remove the seat cushion foam pad. 8. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 9. CAUTION: Care must be taken to prevent damage to the set cushion pan when removing the rivets. Remove the 2 rivets and the OCS ECU. 10. Remove the 2 pin-type retainers from the OCS bladder and seat cushion pan. 11. Feed the OCS hose and pressure sensor through the seat cushion pan opening and remove as an assembly with the bladder. Installation NOTE: If installing an OCS service kit, refer to Occupant Classification Sensor - Service Kit. See: Occupant Classification Sensor - Service Kit 1. Bend the retaining tab back on the pressure sensor component bracket. A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Page 3011 G1-G3 Page 738 P1900 - P1904: Testing and Inspection P1901 P1901 (Part 1) P1901 (Part 2) Transmission Fluid Drain and Refill Fluid - A/T: Service and Repair Transmission Fluid Drain and Refill Transmission Fluid Drain and Refill-Without Torque Converter Drain Plug Material Draining 1. With the vehicle in NEUTRAL position it on a hoist. 2. NOTE: If an internal problem is suspected, drain the fluid through a paper filter. A small amount of metal or friction particles may be found from normal wear. If an excessive amount of metal or friction material is present the transaxle will need to be overhauled. Remove the transaxle drain plug. Refill 1. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). 2. Fill the transaxle with clean automatic transmission fluid. 3. Start the engine and run through all the gears and check fluid level. Page 2572 7. Remove the SJB screw. 8. Disconnect the electrical connectors and remove the SJB. 9. To install, reverse the removal procedure. - Configure the SJB. Refer to Information Bus (Module Communications Network). Page 6977 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 1919 Engine Oil: Fluid Type Specifications Engine Oil ................................................................................................................................................. SAE 5W-20 Premium Synthetic Blend Motor Oil Page 6726 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 5445 Disclaimer Locations View 151-3 (Engine Compartment, 1 Of 2) Page 4781 - To install, tighten to 12 Nm (9 lb-ft). 6. Disconnect the wiring harness retainer and position aside the wiring harness. 7. Remove the ground strap nut and position aside the strap. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the 2 starter motor stud bolts. - Install the upper and lower starter motor stud bolts finger-tight. - Tighten the upper bolt to 25 Nm (18 lb-ft). - Tighten the lower bolt to 25 Nm (18 lb-ft). 9. Remove the starter motor bracket bolt and the starter motor. - To install, tighten to 25 Nm (18 lb-ft). 10. To install, reverse the removal procedure. Page 3030 Page 5913 - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 15. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 5736 Refrigerant Oil: Service and Repair REFRIGERANT OIL ADDING Special Tool(s) Special Tool(s) 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 Diagrams Page 7445 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 1478 Power Steering Pump to Steering Gear Pressure Line Power Steering Line/Hose: Service and Repair Power Steering Pump to Steering Gear Pressure Line Power Steering Pump to Steering Gear Pressure Line Material Page 1276 View 151-11 (Manual Transmission) Page 3764 View 151-10 (Automatic Transmission) Page 3987 3. Remove the 7 retainers and the LH splash shield. 4. Remove the 4 bolts and the cross brace. 5. Remove the bolt for the mount and the 2 bolts for the brace. 6. Remove the rear bolt and remove the brace. 7. Remove the 2 bolts from the mount and remove the mount. Installation 1. Install a new mount onto the brace and install the bolts. ^ Tighten to 40 Nm (30 ft. lbs.). Page 3013 G5-G7 Page 7095 Power Seat Switch: Testing and Inspection Page 5961 ^ 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. Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 3665 Page 7097 Power Seat Switch: Service and Repair SEAT CONTROL SWITCH Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may result in personal injury. - The seat 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Depower the supplemental restraint system (SRS). 2. Remove the recliner handle cover. 3. Remove the seat control switch knob. 4. Remove the 3 screws and the outboard front seat side cushion shield. - If equipped, disconnect the heated seat switch electrical connector. - Disconnect the seat control switch electrical connector. 5. Remove the 3 seat control switch screws. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. 7. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Repower the supplemental restraint system (SRS). Page 7282 Driver/Vehicle Information Display: Diagrams P1400 P1400 Page 2324 Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Special Tool(s) Material Removal 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. Remove the crankshaft pulley. 2. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal. Using the special tool, remove the crankshaft front oil seal. Installation Page 1769 Valve Clearance: Service and Repair Valve Clearance Check 1. Remove the valve cover. 2. CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in these locations. Page 1541 Impact Sensor: Service and Repair Side Impact Sensor - Second Row, C-Pillar SIDE IMPACT SENSOR - SECOND ROW, C-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the C-pillar trim panel. 3. Remove the side impact sensor bolt. 4. Disconnect the electrical connector and remove the side impact sensor. Installation 1. Connect the electrical connector to the side impact sensor. Page 939 Relay Box: Diagrams Smart Junction Box (SJB) Page 3900 Diagrams/Components/Component Location Views System Diagnosis P1309 Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 5869 View 151-18 (Full Body, Right Rear - 2 Of 2) Low Speed Fan Control Relay Page 3703 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Page 6448 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 5338 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 7325 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 2775 Page 4970 Page 5133 Removal and Installation CAUTION: While 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. Drain the power steering fluid into a suitable drain pan. 2. Remove the front bumper cover. 3. Release the power steering fluid cooler hose clamp and disconnect the power steering fluid cooler-to-fluid reservoir hose. 4. Release the clamp and disconnect the power steering gear-to-fluid cooler return hose. 5. Remove the 2 power steering fluid cooler nuts. ^ To install, tighten to 10 Nm (89 inch lbs.). 6. Remove the 2 power steering fluid cooler bolts. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. Remove the power steering fluid cooler. 8. To install, reverse the removal procedure. ^ Fill the power steering system. Page 4028 13. Remove the main control valve body bolts in the sequence shown. 14. NOTE: Do not damage the manual valve. Lift the main control valve body while disconnecting the manual valve link. 15. Depress the retaining tabs and push the solenoid valve body electrical connector down through the transaxle case. 16. Make sure the manual valve control lever does not fall out of the main control valve body while removing from the vehicle. Installation Page 5946 Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 3966 Transmission Cooler: Description and Operation Transaxle Cooling Transmission With an Auxiliary Transmission Fluid Cooler All vehicles with automatic transmissions are equipped with a transmission fluid cooler integral to the radiator which cannot be repaired separately. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to the outside air. The transmission fluid cooling system, with an auxiliary transmission fluid cooler, consists of the following: ^ an in-tank fluid cooler inlet tube ^ a non-repairable in-tank transmission fluid cooler ^ an in-tank fluid cooler return tube ^ an auxiliary fluid cooler Page 117 P0174 Page 1674 P0155 P0155 Description and Operation Oil Temperature Sensor For ECM: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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 77 P0133 Page 6239 View 151-17 (Full Body, Right Rear - 1 Of 2) Locations View 151-12 (Dash Panel) Power Door Lock Switch, Passenger View 151-23 (Right Front Door) Page 1663 View 151-24 (Rear Door (RH Side Shown, LH Side Similar)) Description and Operation Variable Induction Control Actuator: Description and Operation INTAKE MANIFOLD TUNING VALVE (IMTV) Intake Manifold Tuning Valve (IMTV) WARNING: Substantial opening and closing torque is applied by this system. To prevent Injury, be careful to keep fingers away from lever mechanisms when actuated. The IMTV is a motorized actuated unit mounted directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator shaft. There is no monitor input to the PCM with this system to indicate shutter position. The motorized IMTV unit is not energized below approximately 2,600 RPM. The shutter is in the closed position not allowing airflow blend to occur in the intake manifold. Above approximately 2,600 RPM the motorized unit is energized. The motorized unit is commanded on by the PCM initially at a 100 percent duty cycle to move the shutter to the open position, and then falling to approximately 50 percent to continue to hold the shutter open. 1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system. There must be a positive change in voltage from the TP sensor along with the increase in RPM to open the shutter. 2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at high engine speeds to allow both sides of the manifold to blend together. Page 3239 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) VEHICLE SPEED SENSOR (VSS) Typical Vehicle Speed Sensor (VSS) The VSS is a variable reluctance or hall-effect sensor that generates a waveform with a frequency that is proportional to the speed of the vehicle. If the vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM uses the frequency signal generated by the VSS (and other inputs) to control such parameters as fuel injection, ignition control, transmission/transaxle shift scheduling, and torque converter clutch scheduling. Page 7695 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 1154 Locations Page 1740 Exploded View Removal and Installation 1. Remove the battery tray. 2. Remove the bolt and the air cleaner intake pipe. - To install, tighten to 8 Nm (71 lb-in). 3. NOTE: Make sure that the front sponge seal of the intake pipe is seated on the shroud panel. To install, reverse the removal procedure. Page 5239 Front Steering Knuckle: Service and Repair Wheel Knuckle Special Tool(s) Removal 1. Remove the brake disc. 2. Remove and discard the wheel hub nut. 3. Using the special tool, separate the outer CV joint spindle from the wheel hub. 4. Remove the cotter pin and the tie-rod end-to-knuckle nut. 5. CAUTION: Do not use a hammer to separate the tie-rod end from the wheel knuckle or damage to the wheel knuckle can result. CAUTION: Do not damage the tie-rod end boot while installing the special tool. Page 4095 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. Locations View 151-7 (Engine, front) Page 7437 Symbols Part 5 Page 6756 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 2500 Heater Hose: Service and Repair HEATER HOSE Heater Hose To Heater Core Connections Fuel Level Input Fuel Level Sensor: Description and Operation Fuel Level Input FUEL LEVEL INPUT NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Page 7223 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 3026 Special Tool(s) Page 3295 3. CAUTION: Make sure the vapor 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 the tube into the connector. Install the fuel vapor tube quick connect coupling. Pull on the fitting to make sure it is fully engaged. 4. Connect the EVAP canister purge valve electrical connector. 5. Connect the battery ground cable. Page 7809 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 7517 B3-B5 Page 2963 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 6374 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 1539 Impact Sensor: Service and Repair Side Impact Sensor - First Row, B-Pillar SIDE IMPACT SENSOR - FIRST ROW, B-PILLAR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. - RH side shown, LH side similar. 1. Depower the system. 2. Remove the B-pillar trim panel. 3. Disconnect the side impact sensor electrical connector. 4. Remove the bolt and the side impact sensor. Installation Page 5013 Power Distribution Relay: Testing and Inspection Page 5993 Seat Belt: Service and Repair Safety Belt Tongue Rotated on Belt SAFETY BELT TONGUE ROTATED ON BELT 1. Fold the safety belt as indicated. 2. Pull the safety belt tongue over the fold in the safety belt. Page 1348 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 2946 Fuel Level Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 7032 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 4157 1. Remove the halfshaft assembly. 2. To remove the seal only, use the special tool to remove the stub shaft seal. 3. To remove the bearing and seal, use the special tools to remove the stub shaft pilot bearing and seal. Installation 1. NOTE: Lubricate the new stub shaft pilot bearing with rear axle lubricant. To install the bearing, use the special tools and install the stub shaft pilot bearing. 2. NOTE: Lubricate the new stub shaft pilot bearing housing seal with grease. Using the special tools, install the stub shaft pilot bearing housing seal. Page 2652 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Page 4883 Relay Box: Diagrams Smart Junction Box (SJB) Page 3660 Torque Specifications Diagrams Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Diagrams Page 7867 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 1970 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Component Locations Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil Capacity ...................................................................................................................... ........................................................... 266 ml. (9 oz.) Coil on Plug (CoP) #1 Page 7943 3. Through the RH access, disconnect the liftgate window glass electrical harness connector. 4. Disconnect the LH heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the 2 liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. 2 Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the 2 liftgate window glass hinge nuts and the liftgate window glass. To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. - Transfer components as necessary. Page 4661 12. Compress the rear parking brake cable conduit locking tabs and pull the cable assembly through the brake backing plate. Disc brake vehicles 13. Release the rear parking brake cable end from the parking brake actuator lever and compress the cable conduit locking tabs. All vehicles 14. To install, reverse the removal procedure. ^ Adjust the parking brake cable. Front Drive Halfshafts Axle Shaft Assembly: Description and Operation Front Drive Halfshafts Front Drive Halfshafts Front Drive Halfshafts The front drive halfshafts consist of the following components: ^ inner CV joints ^ outer CV joints ^ intermediate shaft/bearing ^ front drive halfshafts The intermediate shaft contains a pressed-on bearing which is only repaired as an assembly. Halfshaft Joint Halfshaft Joint The front drive halfshaft joints consist of the following components: ^ inner CV joints ^ outer CV joints ^ CV joint boot clamps ^ CV joint boots ^ tripod joint housings ^ retainer circlips Locations View 151-8 (Engine, rear) 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 an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable cam timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: Eliminate cruise control actuators. - Eliminate idle air control (IAC) valve. - Better airflow range. - Packaging (no cable). - More responsive powertrain at altitude and improved shift quality. It should be noted that the ETC system includes a warning indicator (wrench light) on the instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage. - Signal return (ground). - TP1 voltage with negative voltage slope (5-0 volts). - TP2 voltage with positive voltage slope (0-5 volts). Accelerator Pedal Position (APP) Sensors Suction Accumulator to Compressor Line Hose/Line HVAC: Service and Repair Suction Accumulator to Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Page 7442 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 1482 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 6505 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. Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6213 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 7292 Symptom Chart (Part 2) General Procedures Valve Spring: Service and Repair General Procedures Valve Spring Free Length 1. Measure the free length of each valve spring. ^ If out of specification, install new components as necessary. Valve Spring Squareness 1. Measure the out-of-square on each valve spring. ^ Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square. Valve Spring Strength Special Tool(s) 1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length. ^ If out of specification, install new components as necessary. Page 1725 Alignment: Service and Repair Toe Adjustment Front Toe Adjustment Front Toe Adjustment 1. Start the engine and center the steering wheel. 2. Turn the engine off. Hold the steering wheel in the straight-ahead position using a suitable holding device. 3. Check the toe settings following the equipment manufacturer's instructions. 4. NOTE: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod is rotated. Remove the steering gear bellows clamp(s). 5. Loosen the tie-rod end jam nut(s). ^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads. Page 4355 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Page 4125 7. CAUTION: Make sure that the plastic straw inside of the lever does not come out. Remove the knob and wiring by pulling straight up on the knob. 8. Carefully pry up the 4 bezel clips and remove the bezel. 9. Remove the gearshift bezel. Installation Page 5080 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Page 6854 OASIS ACTIVATED? Yes. OASIS was activated April 5, 2006. FSA VIN LIST ACTIVATED? Yes. FSA VIN lists will be available through the website by May 15, 2006. Owner names and addresses will be available by May 26, 2006. 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 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. If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ 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 the Special Service Support Center. ^ "MT" labor must be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from the Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Diagrams SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Page 6928 Page 4128 Shifter CVT: Service and Repair Selector Lever Button Selector Lever Button Removal 1. Remove the loose selector lever button by carefully prying the button out with a screwdriver. Installation 1. Install a new selector lever button by pressing the button into the selector lever until it clicks into place. Description and Operation Evaporator Temperature Sensor / Switch: Description and Operation AIR CONDITIONING EVAPORATOR TEMPERATURE (ACET) 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 ACET sensor measures the evaporator air discharge temperature. The ACET sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The PCM sources a low current 5 volts on the ACET circuit. With SIG RTN also connected to the ACET sensor, the varying resistance 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 7755 Front Suspension Spring ( Coil / Leaf ): Service and Repair Front Removal and Installation Strut and Spring Assembly Removal NOTE: LH side is shown, RH side is similar. 1. NOTE: Verify the steering wheel is in the unlocked position before removal. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake jounce hose clip. 3. Pull the brake jounce hose downward slightly to remove the hose from the bracket and position the brake jounce hose aside. 4. Remove the ABS wheel speed sensor harness bolt. 5. NOTE: Use the hex holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Output Shaft Speed (OSS) Sensor View 151-10 (Automatic Transmission) Page 1644 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Locations Page 4213 4. Using the special tools, remove the wheel hub. 5. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 6. Remove the wheel bearing snap ring from the wheel knuckle. FWD vehicles 7. Using the special tools, remove the wheel bearing from the wheel knuckle. 4WD vehicles 8. Using the special tools, press the wheel bearing race from the wheel knuckle. Installation All vehicles Page 6012 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 3873 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 2992 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 14-1 Page 7050 View 151-21 (Passenger Seat) Page 3434 Page 7512 Smart Junction Box (SJB) C2280d Smart Junction Box (SJB) C2280e Page 947 Relay Box: Application and ID Battery Junction Box Page 3883 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 6844 ONE TIME CLAIM REIMBURSEMENT FOR LOCALLY OBTAINED 5/8 INCH AUGER BIT Dealers will be reimbursed for the cost of one auger bit. For this reimbursement, the actual cost of the auger bit must be submitted on one of the initial claims for this recall using the miscellaneous expense code "OTHER". NOTE: Any additional reimbursement claims for an auger bit will result in a charge-back. Attachment II - Labor and Parts Information LABOR ALLOWANCES REQUIRED SPECIAL TOOLS To perform this recall, the technician will require a special drill guide and a 5/8 inch auger bit. ^ Drill Guide: On or about May 12, 2006, one drill guide tool was sent to each dealer at no cost. The tool was shipped by DHL Express Ground Transportation and addressed, "ATTN: Service Manager". Questions regarding the drill guide should be directed to the Special Service Support Center. ^ 5/8 Inch Auger Bit: This tool must be obtained locally. For tool cost reimbursement, refer to Attachment I of this document. PARTS REQUIREMENTS / ORDERING INFORMATION No parts are required for this recall. Attachment III - Technical Information OVERVIEW Page 1579 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Worldwide Diagnostic System (WDS) Special Tool(s) Page 3394 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. P0460 P0460 Page 548 P1274 Service and Repair Cruise Control Switch: Service and Repair SPEED CONTROL SWITCH Removal and Installation 1. Remove the driver air bag module. 2. Remove the 4 steering wheel cover screws and the steering wheel cover. 3. Remove the 4 steering wheel brace nuts and the steering wheel brace. - To install, tighten to 9 Nm (80 lb-in) 4. Disconnect the electrical connectors. 5. Remove the 4 speed control switch screws and the speed control switches. - To install, tighten to 7 Nm (62 lb-in). 6. To install, reverse the removal procedure. Page 813 P2133 Page 5950 1. WARNING: The tightening torque of the air bag RCM retaining bolts is critical for correct system operation. Position the RCM and install the 3 bolts. Tighten to 11 Nm (8 lb-ft). 2. Connect the small RCM electrical connector. 3. Make sure the connector position assurance lever is in the full release position before attempting to connect the large RCM electrical connector. 4. CAUTION: Putting the large RCM electrical wiring 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 wiring connector into the RCM. - CAUTION: Do not push the connector to where the lever pivots and seats itself. Light pressure is needed to get the connector into position on the RCM before using the lever to fully seat the connector. With the large RCM electrical wiring connector uniformly aligned to the RCM, lightly push in until a subtle audible click is heard and a slight resistance is felt. Page 7075 Page 1790 Special Tool Seal Removal Transmission Filter Page 3664 Page 2981 Symbols Part 4 Locations View 151-10 (Automatic Transmission) Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUGS Exploded View Removal 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connectors. 3. Remove the bolts and the ignition coils. 4. NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. Remove the spark plugs. Installation Service and Repair Cruise Control Servo Cable: Service and Repair SPEED CONTROL CABLE Page 3522 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 FRT sensor measures the temperature 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. Page 1286 Brake Light Switch: Service and Repair STOPLAMP SWITCH Removal 1. Disconnect the stoplamp switch electrical connector. 2. Remove the stoplamp switch. Installation 1. CAUTION: Initial installation of the stoplamp switch allows for one adjustment. If additional adjustments are required, install a new stoplamp switch. Rotate the knob counterclockwise to the stop to unlock. 2. With the engine running, fully apply the brake pedal. 3. Install the stoplamp switch and slowly release the brake pedal. 4. Connect the stoplamp switch electrical connector. System Diagnosis P2004 Page 5028 Transfer Case Rear Output Shaft Oil Seal Seals and Gaskets: Service and Repair Transfer Case Rear Output Shaft Oil Seal Transfer Case Rear Output Shaft Oil Seal Special Tool(s) Removal 1. Remove the transfer case rear output shaft flange. 2. Remove the transfer case rear output shaft oil (pinion) seal. Installation 1. Using the special tool, install the transfer case rear output shaft oil (pinion) seal. 2. Install the transfer case rear output shaft flange. Page 6734 Front Subframe Mount: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 7153 4. Rotate the speed control cable cap until the locking tab engages. Page 5874 Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 6955 Part 2 NOTE: Individual components can be removed without following the entire sequence shown. LH and RH stopblocks are not interchangeable. Have an assistant help with sliding the inner roof rack assembly from the upper slide rails. 1. Remove the 4 screws and the roof rack air deflector. - To install, tighten to 5 Nm (44 lb-in). 2. Remove the 2 screws and the 2 roof rack inner rack stop blocks. - To install, tighten to 4 Nm (35 lb-in). 3. Remove the roof rack inner rack. 4. Remove the 2 screws and the roof rack cross bar. - To install, tighten to 4 Nm (35 lb-in). 5. Remove the 6 screws and the 2 roof rack side bars. - To install, tighten to 2 Nm (18 lb-in). 6. Remove the 8 screws and the 2 roof rack side bar bases. - To install, tighten to 2 Nm (18 lb-in). 7. To install, reverse the removal procedure. Steering - Improved Drift/Pull Diagnostics Alignment: By Symptom Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Front Front Door Window Glass: Service and Repair Front FRONT DOOR WINDOW GLASS Removal and Installation 1. Remove the front door trim panel. 2. Remove the screw and the door trim panel bracket. 3. Position the watershield aside. 4. Remove the interior door glass weatherstrip. 5. Connect the window control switch electrical connector. 6. Connect the battery. 7. Using the window control switch, lower the front door window glass to gain access to the front door window glass screws. 8. Disconnect the battery. 9. Disconnect the window control switch electrical connector. 10. Remove the 2 front door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 11. Remove the front door window glass. 12. To install, reverse the removal procedure. - Cycle the front door window glass to make sure it is engaged correctly. Locations View 151-7 (Engine, front) Page 5688 Heater Hose: Service and Repair HEATER HOSE Heater Hose To Heater Core Connections Page 5816 Removal and Installation 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. - When installing a drivers air bag module (soft pack), make sure there are no foreign objects in the steering wheel cavity or in the driver air bag module (soft pack). Failure to do so may result in personal injury in the event of an air bag deployment. - Do not dislodge the fabric from the air bag module (soft pack). In the event that the air bag fabric becomes dislodged, install a new air bag module (soft pack). Failure to do so may result in personal injury in the event of an air bag deployment. - Be careful not to pinch the air bag fabric between the steering wheel and the air bag module housing. In the event the fabric becomes pinched, install a new air bag module (soft pack). Failure to do so may result in the air bag not functioning properly. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The driver air bag (soft pack) and steering wheel can be serviced separately or as an assembly. - In the event of an air bag (soft pack) deployment, the air bag (soft pack) and the steering wheel must be serviced as an assembly. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Page 6000 injury in collisions. 1. NOTE: To access the center and passenger side rear safety belt buckles, pivot the rear seat cushion forward and the rear seat backrest rearward. Remove the bolt and the rear center and RH safety belt buckle assembly. To install, tighten to 47 Nm (35 lb-ft). 2. To install, reverse the removal procedure. 3. Check the active restraint system for correct operation. Page 6822 ONE TIME CLAIM REIMBURSEMENT FOR LOCALLY OBTAINED 5/8 INCH AUGER BIT Dealers will be reimbursed for the cost of one auger bit. For this reimbursement, the actual cost of the auger bit must be submitted on one of the initial claims for this recall using the miscellaneous expense code "OTHER". NOTE: Any additional reimbursement claims for an auger bit will result in a charge-back. Attachment II - Labor and Parts Information LABOR ALLOWANCES REQUIRED SPECIAL TOOLS To perform this recall, the technician will require a special drill guide and a 5/8 inch auger bit. ^ Drill Guide: On or about May 12, 2006, one drill guide tool was sent to each dealer at no cost. The tool was shipped by DHL Express Ground Transportation and addressed, "ATTN: Service Manager". Questions regarding the drill guide should be directed to the Special Service Support Center. ^ 5/8 Inch Auger Bit: This tool must be obtained locally. For tool cost reimbursement, refer to Attachment I of this document. PARTS REQUIREMENTS / ORDERING INFORMATION No parts are required for this recall. Attachment III - Technical Information OVERVIEW Page 5197 Deactivator Switch View 151-14 (Under Dash Panel, LH Side) Page 2004 Seat Pressure Sensor View 151-21 (Passenger Seat) Page 5156 Power Steering Line/Hose: Service and Repair Steering Gear to Fluid Cooler Return Hose Steering Gear to Fluid Cooler Return Hose Material Page 275 P0410 - P0414: Testing and Inspection P0412 P0412 (Part 1) P0412 (Part 2) Page 7600 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 6141 - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 15. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 3648 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 3994 6. Remove the upper transaxle mount through bolt. ^ To install, tighten to 103 Nm (76 ft. lbs.). 7. Remove the 4 upper transaxle mount bolts and remove the mount. ^ To install, tighten to 55 Nm (41 ft. lbs.). 8. To install, reverse the removal procedure. 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 an engine output torque (via throttle angle) based on driver demand (pedal position). It uses an electronic throttle body, the PCM, and an accelerator pedal assembly to control the throttle opening and engine torque. The ETC system replaces the standard cable operated accelerator pedal, idle air control (IAC) valve, 3-wire throttle position sensor (TPS), and mechanical throttle body. Torque based ETC enables aggressive automatic transmission shift schedules (earlier upshifts and later downshifts). This is possible by adjusting the throttle angle to achieve the same wheel torque during shifts, and by calculating this desired torque, the system prevents engine lugging (low RPM and low manifold vacuum) while still delivering the performance and torque requested by the driver. It also enables many fuel economy/emission improvement technologies such as variable cam timing (VCT) (deliver same torque during transitions). Torque based ETC also results in less intrusive vehicle and engine speed limiting, along with smoother traction control. Other benefits of ETC are: Eliminate cruise control actuators. - Eliminate idle air control (IAC) valve. - Better airflow range. - Packaging (no cable). - More responsive powertrain at altitude and improved shift quality. It should be noted that the ETC system includes a warning indicator (wrench light) on the instrument cluster that illuminates when a fault is detected. Faults are accompanied by DTCs and may also illuminate the malfunction indicator lamp (MIL). Electronic Throttle Body (ETB) The Gen II ETB has the following characteristics 1. The throttle actuator control (TAC) motor is a DC motor controlled by the PCM (requires 2-wires). The gear ratio from the motor to the throttle plate shaft is 17:1. 2. There are 2 designs: parallel and in-series. The parallel design has the motor under the bore parallel to the plate shaft. The motor housing is integrated into the main housing. The in-series design has a separate motor housing. 3. Two springs are used: one is used to close the throttle (main spring) and the other is in a plunger assembly that results in a default angle when no power is applied. This is for limp home reasons (the force of the plunger spring is 2 times stronger than the main spring). The default angle is usually set to result in a top vehicle speed of 48 km/h (30 mph). Typically this throttle angle is 7 to 8 degrees from the hard-stop angle. 4. The closed throttle plate hard stop is used to prevent the throttle from binding in the bore (-0.75 degree). This hard stop setting is not adjustable and is set to result in less airflow than the minimum engine airflow required at idle. 5. Unlike cable operated throttle bodies, the intent for the ETB is not to have a hole in the throttle plate or to use plate sealant. The hole is not required in the ETB because the required idle airflow is provided by the plate angle in the throttle body assembly. This plate angle controls idle, idle quality, and eliminates the need for an IAC valve. 6. The throttle position (TP) sensor has 2 signal circuits in the sensor for redundancy. The redundant throttle position signals are required for increased monitoring reasons. The first TP signal (TP1) has a negative slope (increasing angle, decreasing voltage) and the second signal (TP2) has a positive slope (increasing angle, increasing voltage). During normal operation the negative slope TP signal (TP1) is used by the control strategy as the indication of throttle position. The TP sensor assembly requires 4 circuits. 5-volt reference voltage. - Signal return (ground). - TP1 voltage with negative voltage slope (5-0 volts). - TP2 voltage with positive voltage slope (0-5 volts). Accelerator Pedal Position (APP) Sensors Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Material Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake caliper clip. 3. Loosen the brake caliper jounce hose at the brake caliper. ^ To install, tighten to 20 Nm (15 ft. lbs.). 4. Remove the 2 brake caliper dust boot caps. 5. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.) for disc-drum brake system. ^ To install, tighten to 45 Nm (33 ft. lbs.) for 4-wheel disc brake system. 6. Remove the brake caliper. ^ Unthread the brake caliper from the brake caliper jounce hose. 7. NOTE: Make sure that the brake caliper jounce hose is not twisted. To install, reverse the removal procedure. ^ Bleed the brake system. Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 6246 Service and Repair Evaporative Canister Filter: Service and Repair DUST SEPARATOR Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the 2 fuel vapor hoses from the dust separator. 4. Slide the dust separator out of the retainer clip in the emission canister bracket. 5. To install, reverse the removal procedure. Locations View 151-7 (Engine, front) Page 1481 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 FRT sensor measures the temperature 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. Page 1888 5. Remove the transaxle fill plug. 6. Fill the transmission with gear oil until level with the fill level inspection plug hole. 7. NOTE: Use a new gasket and apply sealant on the fill plug. Install the transaxle fill plug. ^ Tighten to 35 Nm (26 ft. lbs.). 8. NOTE: Use a new gasket and apply sealant on the fill level inspection plug. Install the fill level inspection plug. ^ Tighten to 35 Nm (26 ft. lbs.). Steering/Suspension - Front End Click/Pop On Bumps Stabilizer Link: All Technical Service Bulletins Steering/Suspension - Front End Click/Pop On Bumps TSB 09-24-2 12/14/09 CLICK/POP NOISE FROM FRONT STABILIZER BAR END LINK AREA WHEN DRIVING OVER BUMPS - BUILT ON OR BEFORE 10/9/2009 FORD: 2005-2010 Escape MERCURY: 2005-2010 Mariner ISSUE Some 2005-2010 Escape, Escape Hybrid, Mariner and 2006-2010 Mariner Hybrid vehicles built on or before 10/9/2009 may exhibit a click/pop noise from the front end when going over bumps. This may be due to the stabilizer bar end link to strut (upper) attachment. ACTION Follow the service procedure to correct the condition. SERVICE PROCEDURE 1. Using chassis ears, can the click/pop noise be isolated to the stabilizer bar end links? a. No - Do not continue with this procedure. Follow normal Workshop Manual (WSM), Section 204-00 diagnostics. b. Yes - Proceed to Step 2. 2. Inspect the stabilizer bar end link to strut (upper) attachment nuts for signs of looseness. Is any evidence present of loose upper nuts? a. No - Replace stabilizer bar end links and install revised upper nuts per WSM, Section 204-01. NOTE THE REVISED, TALLER NUTS CANNOT BE INSTALLED ON THE STABILIZER BAR END LINK LOWER ATTACHMENT. b. Yes - Remove and replace both upper nuts with revised, taller nuts per WSM, Section 204-01. Torque to 46 lb-ft (63 N.m). It is not necessary to replace the stabilizer bar end link. 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 092402A 2005-2010 Escape, 1.1 Hrs. Mariner, Escape Hybrid, 2006-2010 Mariner Hybrid: Diagnose With Chassis Ears And Road Test, Inspect Stabilizer Bar End Links, Replace Four (4) Stabilizer End Link Nuts Or Stabilizer Bar End Links (Do Not Use With Any Page 1334 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Specifications Torque Specifications Page 7551 97-3 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 6252 Parking Assist Switch: Service and Repair PARKING AID SWITCH Removal and Installation 1. Remove the instrument panel center finish panel. 2. Press the retaining tabs and remove the parking aid switch. 3. To install, reverse the removal procedure. Page 5858 Clockspring Assembly / Spiral Cable: Description and Operation CLOCKSPRING The clockspring: - is mounted on the steering column, behind the steering wheel. - continuously transfers electrical signals from the restraints control module (RCM) to the driver air bag module. Page 4920 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 4757 Alternator: Service and Repair GENERATOR Removal and Installation CAUTION: Do not allow any metal object to come in contact with the generator housing and internal diode cooling fins. A short circuit may result and burn out the diodes. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. 3. Rotate the front end accessory drive belt tensioner counterclockwise and position the accessory drive belt aside. 4. Position the generator B+ protective cover aside and remove the generator B+ terminal nut. - To install, tighten to 8 Nm (71 lb-in). 5. Position the generator B+ cable aside. Page 2221 Valve Cover: Service and Repair Valve Cover Page 4398 2. CAUTION: Do not over-tighten the pinion nut. CAUTION: Refer to the rotational torque previously recorded with an in-lb torque wrench. CAUTION: If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 678 Nm (500 ft. lbs.) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed. Using the special tool install the pinion nut. 3. Install the transfer case. Main Control Cover and Gasket Valve Body: Service and Repair Main Control Cover and Gasket Main Control Cover and Gasket Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery tray. 3. Remove the breather tube and disconnect the Mass Air Flow (MAF) sensor electrical connector. 4. Remove the intake tube and the air cleaner cover. 5. Disconnect the vent hose from the main control cover. Description and Operation Leak Detection Solenoid: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid For information on the CV solenoid, refer to the description of the Evaporative Emission Systems. Page 6974 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 7241 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 Page 7547 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 7159 3. Rotate the speed control cable cap until the locking tab engages. 4. Connect the speed control cable to the throttle lever and accelerator cable bracket. 5. Install the accelerator cable snow shield. Page 1015 View 151-19 (Center Console) Page 7270 Body/Frame - Front/Rear Squeak/Creak Noises Front Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 6227 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 6824 1. Without pulling the headliner down beyond its natural hanging rest position, carefully inspect the structural foam blocks mounted at the passenger and drivers side front corners on the top of the headliner to see if they have one (1) or two (2) indentations. See Figure 2. ^ If the blocks have only one (1) indentation, proceed to DISASSEMBLY FOR MODIFICATION. ^ If the blocks have two (2) indentations, no modification is required. Proceed to ASSEMBLY. DISASSEMBLY FOR MODIFICATION 1. Remove the interior lamp lens. 2. Remove the two (2) screws and the interior lamp, then disconnect the electrical connector. 3. Proceed to STRUCTURAL FOAM BLOCK MODIFICATION. STRUCTURAL FOAM BLOCK MODIFICATION 1. Using fender covers, seat covers or suitable rags, cover the defroster and instrument panel ducts so chips cannot fall into the heater plenum while drilling. 2. Install a drill stop or apply suitable tape onto the drill bit 140 mm (5-1/2 in) from the end of the cutting portion of the bit (not from the threaded tip). See Figure 3. 3. CAUTION: The weight of the tool when positioned on the foam block increases the risk of headliner damage. Hold the headliner up when the tool is positioned on the foam block. Page 7446 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 7031 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 6272 Driver/Vehicle Information Display: Diagrams Heated Seat Module, Driver Side Front View 151-20 (Driver Seat) Page 4899 Page 3590 Fuel Temperature Sensor: Description and Operation Fuel Rail Temperature (FRT) Sensor FUEL RAIL TEMPERATURE (FRT) SENSOR Fuel Rail Temperature (FRT) Sensor The FRT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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 FRT sensor measures the temperature 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. Diagrams Page 5738 4. Fill the dye/lubricant injector with the correct amount of clean PAG oil. 5. Install the dye/lubricant injector between the low-side gauge port valve and the refrigerant station or manifold gauge set. 6. Open all the valves and charge the refrigerant system. Page 15 P0021 Page 1191 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 3772 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 5428 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Page 2763 Air Flow Meter/Sensor: Diagrams Locations View 151-7 (Engine, front) Page 1082 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 Service and Repair Heater Core Case: Service and Repair AUXILIARY HEATER CORE HOUSING Removal and Installation 1. Drain the engine coolant. 2. Release the clamps and disconnect the heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. If equipped with A/C, remove the evaporator core housing. 5. NOTE: Carefully remove the heater core housing to avoid spilling engine coolant in the passenger area. Remove the 3 nuts and the heater core housing. - Transfer any necessary external components from the old evaporator core housing to the new evaporator core housing. 6. NOTE: Lubricate the coolant hoses with plain water only, if needed. To install, reverse the removal procedure. Fill and bleed the engine cooling system. Drivetrain - Whine Noise at 20-45 MPH Axle Shaft Assembly: Customer Interest Drivetrain - Whine Noise at 20-45 MPH TSB 05-10-7 05/30/05 DRIVELINE WHINE 20-45 MPH (32-72 KM/H) FORD: 2001-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2001-2006 Escape and 2005-2006 Mariner vehicles equipped with a CD4E transaxle may exhibit a driveline whine at 20-45 MPH (32-72 Km/h) during light acceleration or deceleration. The sound may be more pronounced on vehicles equipped with steel wheels. ACTION If the whine noise occurs at the specified speed range 20-45 MPH (32-72 Km/h) during light acceleration or deceleration, install new dampened halfshaft assemblies. The revised halfshafts are designed to minimize the whine, however, a small amount of noise may be inherently characteristic. The dampened axle halfshafts will not correct driveline noises below or above 20-45 MPH (32-72 Km/h). Refer to Workshop Manual Section 307. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051007A 2001-2004 Escape 1.1 Hrs. Replace The Front Halfshafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) 051007B 2005-2006 Escape/Mariner 1.4 Hrs. Replace The Front Half shafts, Includes Time For Road Test To Verify Concern (Do Not Use With 4462A, 3329A) DEALER CODING CONDITION BASIC PART NO. CODE 3A427 42 Disclaimer Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 812 P2132 Page 375 P0622 Page 1700 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Page 5070 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 4926 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). Locations View 151-12 (Dash Panel) Page 6502 Symbols Part 5 Page 7315 Mechanical Returnless Fuel Pump Module (FPM) Page 4145 2. To remove the seal only, use the special tool to remove the stub shaft seal. 3. To remove the bearing and seal, use the special tools to remove the stub shaft pilot bearing and seal. Installation 1. NOTE: Lubricate the new stub shaft pilot bearing with rear axle lubricant. To install the bearing, use the special tools and install the stub shaft pilot bearing. 2. NOTE: Lubricate the new stub shaft pilot bearing housing seal with grease. Using the special tools, install the stub shaft pilot bearing housing seal. 3. CAUTION: Inspect the inboard CV joint seal journal for rust or nicks/scratches prior to installing the halfshaft. If necessary, polish the seal Service and Repair Parking Brake Control: Service and Repair Parking Brake Control Removal and Installation 1. Remove the floor console. 2. Remove the parking brake control boot. ^ Pull the parking brake control boot up and over the lever. 3. Release the parking brake control. 4. Remove the front cable adjusting nut. 5. Remove the 4 parking brake control bolts. ^ To install, tighten to 24 Nm (18 ft. lbs.). 6. Disconnect the warning indicator switch electrical connector. 7. Remove the parking brake control. ^ Disconnect the front parking brake cable. 8. To install, reverse the removal procedure. ^ Adjust the parking brake cable. Page 7966 Removal WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury. 1. Remove the 4 A-pillar passenger assist handle covers, the 4 bolts and the 2 A-pillar passenger assist handles. 2. Remove the 2 windshield side garnish mouldings. 3. Open the front overhead console door, remove the 2 screws and the overhead console. - If equipped, disconnect the electrical connector. 4. Remove the interior rear view mirror. 5. Remove the 6 screws, 2 sun visors and 2 clips. 6. Partially lower the front portion of the headliner and block with a suitable material. 7. Remove the cowl panel grille. 8. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld. 9. NOTE: Lubricate the urethane adhesive with water to aid the special tool when cutting. Using the special tool, cut the urethane adhesive from the windshield glass starting at the top center and working toward the bottom corners. P2070 P2070 Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE PIPE Page 5419 1. Using the special tools, install a new wheel bearing into the wheel knuckle. 2. Install the wheel bearing snap ring. 3. Using the special tools, install the wheel hub into the wheel bearing. FWD vehicles 4. Install the ABS wheel speed sensor ring. 5. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 4WD vehicles 6. Install the wheel knuckle. Page 3591 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 3587 Page 1967 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 4058 Clutch Pedal Assembly: Service and Repair Clutch Pedal Removal and Installation 1. Disconnect the master cylinder push rod. 2. Remove the 2 clutch master cylinder nuts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 3. Remove the clutch pedal and bracket assembly nut. ^ To install, tighten to 23 Nm (17 ft. lbs.). 4. Remove the clutch pedal and bracket assembly. 5. To install, reverse the removal procedure. Page 7448 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 Locations View 151-14 (Under Dash Panel, LH Side) Page 392 P0704 Page 6606 6. Remove the exterior door handle by sliding the handle towards the rear of the vehicle. 7. Remove the 2 exterior door handle seals. Exterior Rear Door Handle Reinforcement 8. Disconnect the exterior door handle actuating rod. 1 Open the clip. 2 Disconnect the actuating rod. 9. Slide the exterior door handle toward the front of the vehicle and remove the reinforcement. 10. To install, reverse the removal procedure. Page 232 P0331 Page 5999 Seat Belt Buckle: Service and Repair Rear Safety Belt Buckle REAR SAFETY BELT BUCKLE Torx Bit, Safety Belt Bolt Special Tool(s) Removal and Installation WARNING: All safety belt assemblies including retractors, buckles, belt tension sensor (BTS), if equipped, front seat belt buckle support assemblies (slide bar), if equipped, shoulder belt height adjusters, if equipped, child safety seat tether bracket assemblies, if equipped, and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies 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 and new assemblies installed if either damage or incorrect operation is noted. The Automatic Locking Retractor (ALR) feature of the safety belt retractor must be checked by a qualified technician to verify that the ALR feature for a child seat is 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 inspected according to the functional inspection procedures. Failure to replace the belt and retractor assembly could increase the risk of Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Locations View 151-8 (Engine, rear) Page 3454 Fuel Pump Relay: Testing and Inspection Page 2191 2006-2007 Mariner Hybrid 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) 062104A Operation A: 2001-2007 2.0 Hrs. Ranger 2.3L: Replace Crankshaft Pulley, Includes Time To Lock Engine Valve Timing Using Special Tools (Do Not Use With 6312A) DEALER CODING CONDITION BASIC PART NO. CODE 6312 D4 Disclaimer Page 823 P2198 Page 7485 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 3615 Removal and Installation 1. Remove the screw, pin-type retainer and the accelerator control cover shield. - To install, tighten to 10 Nm (89 lb-in). 2. NOTE: Vehicles use either a push-on design or slide-on design accelerator cable connector at the throttle body. The slide-on design supersedes the push-on design and is used as a replacement on all vehicles. Disconnect the accelerator cable from the throttle body. Locations View 151-10 (Automatic Transmission) Diagrams Page 2354 Page 3226 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 1566 View 151-21 (Passenger Seat) Page 901 Compressor Clutch Relay: Description and Operation AIR CONDITIONING CLUTCH RELAY (A/CCR) NOTE: The PCM PIDs WAC and WACF are used to monitor the A/CCR output. The A/CCR (may be referred to as the wide open throttle A/C cutoff [WAC] relay) is wired normally open. 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 communications network). 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 A/CCR output, closing the relay contacts and sending voltage to the A/C clutch. Page 5721 Start the engine. 5. Open the high-pressure valve. 6. Open the injector loop kit valves and inject the fluorescent dye into the refrigerant system. 7. Close the high-pressure valve to allow the pressure inside the injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the injector loop kit while the A/C compressor is operating. Close the valves on the injector loop kit. 9. NOTE: Leave all the valves on the special tool closed when not in use. Page 7058 Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The driver seat and passenger seat are similar. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat and depower the supplemental restraint system (SRS). 2. Remove the 4 front seat track bolts. - To install, tighten to 23 Nm (17 lb-ft). 3. Disconnect the wiring harness from the front seat track and remove the front seat track. 4. To install, reverse the removal procedure. - Transfer components as necessary. 5. Install the front seat and repower the supplemental restraint system (SRS). Page 1279 System Diagnosis P0611 Page 7897 Page 5083 5. Lower the vehicle back down. 6. Place vehicle on alignment rack and measure the alignment to confirm the desired camber change was achieved. NOTE DO NOT ADJUST THE ALIGNMENT SETTINGS (INDIVIDUAL CAMBER) BEYOND THE RELEASED SPECIFICATIONS. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE FRONT W6 Disclaimer System Diagnosis P0575 - P0579: Testing and Inspection P0579 (Part 1) P0579 (Part 2) Page 1812 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 6245 Page 7823 Trailer Lamps: Pinpoint Tests Smart Junction Box (SJB) C2280c Trailer Tow C439 Test Y: Trailer Lamps Are Inoperative PINPOINT TEST Y: THE TRAILER LAMPS ARE INOPERATIVE Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. 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 4369 Page 6190 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Page 6593 View 151-23 (Right Front Door) Page 3078 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Page 7043 Page 5555 Cabin Air Filter: Description and Operation Page 2608 Fuel Pump Relay: Testing and Inspection System Diagnosis P0645 - P0649: Testing and Inspection P0645 (Part 1) P0645 (Part 2) Page 4841 Page 7506 Courtesy Lamp: Diagnostic Trouble Code Descriptions B1314-B1335 B1342-B2902 Page 6508 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 4130 6. Remove the set screw. 7. Remove the knob and wiring by pulling straight Up on the knob. 8. Remove and discard the shifter straw by pulling it straight up. Installation Page 5805 View 151-21 (Passenger Seat) Vehicle - Tow Capability/Service Kit Requirements Towing Information: Technical Service Bulletins Vehicle - Tow Capability/Service Kit Requirements TSB 06-7-1 04/17/06 NEUTRAL TOW CAPABILITY - SERVICE KIT REQUIREMENTS FORD: 2004-2006 Focus 2004 F-150 Heritage 2004-2005 Explorer Sport Trac 2004-2006 Escape, Explorer, F-150-350 Series, Ranger 2005-2006 Escape Hybrid 2007 Explorer Sport Trac LINCOLN: 2006 Mark LT MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 06-4-5 to update the vehicle neutral tow application chart. ISSUE Various vehicles are neutral tow capable. Refer to the following chart to determine neutral tow capability for specific vehicle applications, and to determine if a Service Kit is required to make the vehicle neutral tow capable. Page 7791 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 3711 Page 6855 ONE TIME CLAIM REIMBURSEMENT FOR LOCALLY OBTAINED 5/8 INCH AUGER BIT Dealers will be reimbursed for the cost of one auger bit. For this reimbursement, the actual cost of the auger bit must be submitted on one of the initial claims for this recall using the miscellaneous expense code "OTHER". NOTE: Any additional reimbursement claims for an auger bit will result in a charge-back. Attachment II - Labor and Parts Information LABOR ALLOWANCES REQUIRED SPECIAL TOOLS To perform this recall, the technician will require a special drill guide and a 5/8 inch auger bit. ^ Drill Guide: On or about May 12, 2006, one drill guide tool was sent to each dealer at no cost. The tool was shipped by DHL Express Ground Transportation and addressed, "ATTN: Service Manager". Questions regarding the drill guide should be directed to the Special Service Support Center. ^ 5/8 Inch Auger Bit: This tool must be obtained locally. For tool cost reimbursement, refer to Attachment I of this document. PARTS REQUIREMENTS / ORDERING INFORMATION No parts are required for this recall. Attachment III - Technical Information OVERVIEW Page 2193 Harmonic Balancer - Crankshaft Pulley: Diagrams Lower End Components-Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Page 6368 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 1822 Condenser Connection Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Remove the RH splash shield. 5. If equipped, disconnect the block heater electrical connector. 6. Remove the compressor to condenser discharge line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the compressor to condenser discharge line from the compressor. - To install, tighten to 20 Nm (15 lb-ft). 8. Remove the condenser core peanut fitting nut and disconnect the condenser core peanut fitting compressor. - To install, tighten to 8 Nm (71 lb-in). 9. Remove the compressor to condenser discharge line. 10. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Low Speed Fan Control Relay Service and Repair Auxiliary Water Pump: Service and Repair AUXILIARY COOLANT FLOW PUMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on hoist. 2. Drain the engine coolant. 3. Remove the lower splash shield. 4. Release the 2 clamps and disconnect the 2 auxiliary coolant flow pump heater hoses. 5. Disconnect the auxiliary coolant flow pump electrical connector. 6. Remove the 2 bolts and the auxiliary coolant flow pump. - To install, tighten to 7 Nm (62 lb-in). 7. NOTE: Lubricate the coolant hoses with water if needed. To install, reverse the removal procedure. Fill the engine cooling system. Adjustments Parking Brake Shoe: Adjustments Parking Brake Shoe and Lining Adjustment Special Tool(s) Special Tool(s) 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Make sure the parking brake is fully released. Using the release handle, release the parking brake control. 3. Remove the rear brake disc. 4. Using the special tool, measure the inside diameter of the drum portion of the rear brake disc and set the locking screw. ^ Record the measurement. 5. Place the special tool over the widest diameter of the parking brake shoes. 6. Adjust the parking brake shoe clearance to 1.07 mm (0.04 inch) less than the inside diameter of the drum portion of the rear brake disc. ^ Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc clearance. 7. Install the rear brake disc. 8. Test the parking brake for normal operation. Page 5927 13. Release the side air bag module deployment chute J-clip from around the side air bag module. 14. Feed the side air bag module deployment chute, J-clips, and hook and loop retainer out through the side air bag module seat back foam opening. 15. Continue to roll seat trim cover up to access the side air bag module. 16. Detach the 2 side air bag module wiring harness retainers from the seat backrest frame. 17. Remove the 2 side air bag module nuts and remove the side air bag module. Installation 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 Page 5106 6. Rotate the front wheel spindle tie-rods to increase or decrease the front toe. 7. CAUTION: Hold the tie-rod end stationary with a wrench while tightening the nut, or damage to the boot can occur. NOTE: Do not disturb the toe settings while tightening the nut(s). Tighten the tie-rod end jam nut(s). 8. Install the steering gear bellows clamp(s). 9. Check the toe settings. Follow the equipment manufacturer's instructions. Rear Rear Toe Adjustment 1. CAUTION: The cam nut and cam bolt area must be free of debris to ensure proper clamping. NOTE: Clean the general area of the joint to prevent debris from entering the joint. Clean the area using only mild liquids. NOTE: Jounce the vehicle to make sure that the suspension is in its normal, at-rest position. Check the toe setting using suitable wheel alignment equipment. Page 5651 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 2356 NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. Install the special tool in the slots on the rear of both camshafts. 7. Remove the engine plug bolt. 8. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. Install the special tool. 9. Install the special tools. Page 2222 Removal 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 ignition coil-on-plugs. 3. Disconnect the crankcase vent hose. 4. Remove the 2 coolant vent tube bracket nuts. ^ Position the vent tube and brackets aside. 5. Disconnect the camshaft position(CMP) sensor electrical connector. 6. Disconnect the fuel rail pressure and temperature sensor electrical connector. 7. Disconnect the cylinder head temperature(CHT) sensor electrical connector. 8. Disconnect the vacuum tube from the intake manifold. ^ Detach the pin-type retainer and position the vacuum tube aside. 9. Remove the 2 accelerator cable bracket nuts. ^ Position the accelerator cable and brackets aside. 10. Remove the power steering tube bracket nut. ^ Position the power steering tube and bracket aside. 11. Detach all of the wiring harness retainers from the valve cover studs and position the harness aside. 12. Remove the 14 valve cover retainers, the valve cover and gasket. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Clean and inspect the sealing surfaces. Page 1027 Page 6579 Front Door Panel: Service and Repair FRONT DOOR TRIM PANEL Escape Is Shown, Mariner Is Similar Removal and Installation 1. NOTE: LH side is shown; RH side is similar. Page 4891 Relay Box: Application and ID Battery Junction Box Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 4512 Disclaimer Page 5293 Part 2 Removal and Installation All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery. Escape Hybrid 3. Remove the steering gear. 4. If equipped with 4WD, remove the rear engine mount bracket. 1 Remove the 2 nuts. 2 Remove the bolt. To install, tighten to 90 Nm (66 lb-ft). 3 Remove the rear engine mount bracket. All vehicles except Escape Hybrid 5. Remove the 2 rear transaxle mount nuts and bolt - To install, tighten to 90 Nm (66 lb-ft). Rear Door Glass, Frames and Mechanisms - Exploded View Rear Door Window Glass: Service and Repair Rear Door Glass, Frames and Mechanisms Exploded View REAR DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 6273 Driver/Vehicle Information Display: Description and Operation INFORMATION AND MESSAGE CENTER The message center is a fixed format LCD display, integrated into the instrument cluster. The message center functions are controlled by the message center switches. The message center displays important vehicle information by constantly monitoring different vehicle systems. The message center notifies the driver of a potential vehicle problem by displaying a warning message pertaining to the system in which a fault has been detected. Page 3684 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 3992 Transmission Mount: Service and Repair LH Transaxle Support Insulator-LH Special Tool(s) Removal and Installation 1. Disconnect the breather tube and Mass Air Flow (MAF) sensor. Low Speed Fan Control Relay Page 7711 Fog/Driving Lamp Relay: Testing and Inspection Page 7230 Symbols Part 5 Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking Points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Page 2024 Page 3596 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Page 5617 9. Clean the O-ring seal grooves with a 30 cm (1 foot) 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 new, green, O-ring seals. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. Install the O-ring seals. Lubricate the O-ring seals with mineral oil. Page 7495 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Locations View 151-14 (Under Dash Panel, LH Side) Transfer Case Rear Output Shaft Flange Output Yoke/Flange: Service and Repair Transfer Case Rear Output Shaft Flange Transfer Case Rear Output Shaft Flange Special Tool(s) Removal 1. Remove the transfer case. 2. CAUTION: Rotational torque of the transfer case rear output shaft flange must be measured and recorded using an in-lb torque wrench for correct pinion bearing preload when reassembled. Using the special tool to hold the flange, remove the pinion nut. 3. CAUTION: Mark the transfer case rear output shaft flange relative to the pinion spline. Using the special tool, remove the transfer case rear output shaft flange. Installation 1. CAUTION: Install the transfer case rear output shaft flange to engage the spline as previously marked. Install the transfer case rear output shaft flange. Page 6503 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. Seat Pressure Sensor Page 3262 A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 4329 View 151-10 (Automatic Transmission) Page 6146 2. 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 component failure. - 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. Feed the OCS service kit components (hose, pressure sensor, ECU, wire harness, and connectors) through the seat cushion pan opening. 3. NOTE: - When installing a service part occupant classification sensor, the seat wire harness pressure sensor electrical connector is not used. - Make sure the pressure sensor hose is not kinked during installation. Install the OCS components to the seat cushion pan. 1 Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 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. Body - Door Seal Squeaking Weatherstrip: Customer Interest Body - Door Seal Squeaking TSB 05-22-11 11/14/05 DOOR SEAL SQUEAKS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 Escape, 2005 Escape Hybrid and Mariners may exhibit squeaks from the shedlip seal for the doors. This seal runs along the top edge of the doors, above the top section of the individual door inner seals. This is most likely to be noticed at slow speeds and when the body is put into a twist. ACTION Replace the seals. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052211A 2001-2005 Escape, 2005 0.2 Hr. Escape Hybrid, 2005 Mariner: Replace The Shedlip Seal For Both Doors DEALER CODING CONDITION BASIC PART NO. CODE 7851222 41 OASIS CODES: 110000, 702000 Disclaimer Power Door Lock Switch, Passenger View 151-23 (Right Front Door) Page 219 P0316 Page 4599 Brake Shoe: Adjustments Brake Shoe Adjustment Special Tool(s) 1. Remove the brake drum. 2. Using the special tool, measure the inside diameter of the brake drum. 3. Position the special tool on the brake shoes and linings and adjust accordingly. 4. Install the brake drum. Brake Disc Machining Brake Rotor/Disc: Service and Repair Brake Disc Machining Brake Disc Machining Special Tool(s) Material Brake Disc Machining 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: 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 makes 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 (if equipped) aside. 2. Machine the brake disc using the on-car brake lathe. 1. Install the hub adapter and silencer belt, if necessary. 2. Install the cutting lathe. 3. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated reading (TIR) target is 0.000 mm (0.000 inch), and the 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 cause the bit to heat up and wear faster. Heavier cuts 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. 3. Remove the metal shavings. 4. NOTE: It is not necessary to install new brake pads if the friction material properties are within specification. Refer to Specifications. Install the brake caliper and brake caliper anchor bracket. Page 7652 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 5068 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 1935 Start the engine. 5. Open the high-pressure valve. 6. Open the injector loop kit valves and inject the fluorescent dye into the refrigerant system. 7. Close the high-pressure valve to allow the pressure inside the injector loop kit to equalize with the suction side of the refrigerant system. 8. NOTE: Close the valves on the injector loop kit while the A/C compressor is operating. Close the valves on the injector loop kit. 9. NOTE: Leave all the valves on the special tool closed when not in use. Capacity Specifications Coolant: Capacity Specifications Engine Coolant Capacity ..................................................................................................................... ........................................................... 7.6 qts. (7.2L) Specifications Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. Page 2594 Main Relay (Computer/Fuel System): Testing and Inspection Page 1715 Alignment: Specifications General Specifications Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Wheel Cylinder Material Removal and Installation 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. 1. Remove the brake shoes. 2. Disconnect the brake line fitting nut. ^ To install, tighten to 15 Nm (11 ft. lbs.). 3. Remove the 2 wheel cylinder bolts and remove the wheel cylinder. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. ^ Bleed the brake hydraulic system. Locations View 151-8 (Engine, rear) 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 Locations View 151-10 (Automatic Transmission) Description and Operation Seat Belt Tension Sensor: Description and Operation SAFETY BELT TENSION SENSOR The safety belt tension sensor: - is part of the front outboard passenger safety belt and retractor assembly. - is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a 3-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, when the child safety seat is installed according to manufacturer instructions. 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. Page 398 P0705 - P0709: Testing and Inspection P0708 P0708 (Part 1) P0708 (Part 2) Page 1136 Power Mirror Switch: Testing and Inspection Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT BUMPER COVER Escape Is Shown, Mariner Is Similar (Part 1) Page 1081 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 2121 Lifting Points 1. CAUTION: Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. The lifting points are part of the uni-body structure. Page 4878 Relay Box: Locations Battery Junction Box Page 3117 Air Flow Meter/Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the mass air flow (MAF) sensor electrical connector. 3. Remove the 4 nuts and the MAF sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 7922 Page 6315 D1-D2 Normal Operation The audio unit receives signals from the GPS satellites through the GPS antenna and computes the vehicle position. Possible Causes - GPS antenna - audio unit Test E: The Navigation System Does Not Operate Correctly - The Navigation System Is Inaccurate PINPOINT TEST E: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - THE NAVIGATION SYSTEM IS INACCURATE Page 1940 1. Prior to recovery, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant center to the low- and high-pressure 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 has been recovered, switch the power supply OFF. 5. Allow the system to set for approximately 2 minutes and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Service and Repair Luggage Rack: Service and Repair ROOF RACK Part 1 Page 6154 View 151-21 (Passenger Seat) Page 3923 3. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 4. Adjust the shift cable. Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 6969 Symbols Part 5 Page 3001 Smart Junction Box (SJB) C2280a Smart Junction Box (SJB) C2280b Test A: The Powertrain Control Module (PCM) Does Not Respond to The Diagnostic Tool PINPOINT TEST A: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Page 3886 Symbols Part 2 Service and Repair Fluid - M/T: Service and Repair Transaxle Draining and Filling Material 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the drain plug and drain the fluid. 3. NOTE: Use a new gasket and apply sealant on the drain plug. Install the drain plug. ^ Tighten to 35 Nm (26 ft. lbs.). 4. Remove the fill level inspection plug. Page 1436 Removal And Installation Seat Cushion: Service and Repair Removal And Installation Front Seat Cushion FRONT SEAT CUSHION Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. The side impact sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these instructions may result in personal injury. NOTE: - The passenger seat is equipped with an occupant classification sensor (OCS) system and is replaced as an assembly. - The power seat and manual seat are similar. 1. WARNING: To reduce the risk of serious personal injury, read and follow all warnings, cautions and notes in the supplemental restraint system (SRS) depower/repower procedure. Failure to follow these instructions may result in personal injury. Remove the front seat cushion cover and depower the supplemental restraint system (SRS). 2. Remove the front seat cushion. 3. To install, reverse the removal procedure. 4. Install the front seat cushion cover and repower the supplemental restraint system (SRS). Rear Seat Cushion REAR SEAT CUSHION Removal and Installation 1. Release the latch and tilt the rear seat cushion to the forward position. 2. Release the locking tab and slide the rear seat cushion outward to remove. 3. To install, reverse the removal procedure. Front Seat Cushion Cover FRONT SEAT CUSHION COVER Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Page 3315 Leak Detection Valve: Description and Operation CANISTER VENT (CV) SOLENOID Typical Canister Vent (CV) Solenoid During the EVAP leak check monitor, the CV solenoid seals the EVAP canister from the atmospheric pressure. This allows the EVAP canister purge valve to obtain the target vacuum in the fuel tank during the EVAP leak check monitor. Page 4944 Fuse: Locations Battery Junction Box Page 7505 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, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or UBP circuits fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for SJB, refer to Body Control Systems (Multifunction Electronic Control Module). - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out the 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. See: Symptom Related Diagnostic Procedures Page 8038 Diagrams Page 4503 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System (ABS) Module Material 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 the vehicle as-built data and calibrated. 1. Remove the hydraulic control unit (HCU). 2. Remove the 3 ABS module screws. ^ To install, tighten to 2 Nm (18 inch lbs.). 3. Remove the ABS module. 4. To install, reverse the removal procedure. Fuel Level Input Fuel Level Sensor: Description and Operation Fuel Level Input FUEL LEVEL INPUT NOTE: The Ford GT will use a piezoelectric sonar type fuel level sensor. The sensor is located in the tank and the sensor signal is provided as a communications network message by the instrument cluster to the PCM. The fuel level input (FLI) is either a hard wire signal input to the PCM from the fuel pump (FP) module or a communications network message. Most vehicle applications use a potentiometer type FLI sensor connected to a float in the FP module to determine fuel level. Page 2804 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Page 1298 Page 2687 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Page 4886 Page 1724 Alignment: Service and Repair Lean Correction Lean Correction NOTE: When installing a new coil spring, install a new spring with the same part number and the same spring code. Refer to the Vehicle Certification (VC) label on the driver's side door. 1. Measure the distance from the wheelhouse opening to the center of the wheel and tire at the same point on both sides of the vehicle. 2. If the difference exceeds 10 mm (0.4 inch), a lean correction is necessary. 3. Remove the higher side coil spring. 1 If the original coil spring exceeds the height of the new one by 10 mm (0.4 inch), install the new coil spring in the vehicle. 2 If the original coil spring is shorter than the new one by 10 mm (0.4 inch), remove the low side coil spring from the vehicle. 4. Compare all 3 coil springs and select the 2 most evenly matched for installation. Service and Repair Hydraulic Hose: Service and Repair Clutch Hydraulic Fluid Tubes 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, wash it immediately with water. 1. Remove the engine air cleaner. 2. Disconnect the clutch hydraulic fluid tube fitting from the clutch master cylinder. ^ Plug the clutch master cylinder. ^ Plug the clutch hydraulic fluid tube. 3. Disconnect the clutch hydraulic fluid tube fitting from the clutch slave cylinder-to-clutch hydraulic fluid tube adapter. ^ To install, tighten to 25 Nm (18 ft. lbs.). 4. Remove the clutch hydraulic fluid tube. 5. To install, reverse the removal procedure. ^ Bleed the air from the system. Page 1016 Air Bag Control Module: Diagrams Page 6097 Impact Sensor: Description and Operation 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 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. - Vehicle sensor orientation is critical for correct 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 correctly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. For these vehicles, the SRS uses up to 5 satellite sensors in addition to the RCM. The RCM is mounted to the center tunnel beneath the console. All vehicles will have a front impact severity sensor and it is located in the front-center of the vehicle, mounted on the radiator support bracket. If the vehicle is equipped with safety canopies, there are 4 additional side impact sensors. The 4 additional sensors are located at the base of each B-pillar and mounted on the C-pillar. The LH and RH C-pillar mounted side impact sensors are interchangeable. Mounting orientation is critical for correct operation of all impact and rollover sensors. Page 336 P0534 Page 5129 Power Steering Fluid: Specifications Power Steering Fluid Type ................................................................................................................................................ Motorcraft MERCON(R) ATF Diagrams Exhaust Pipe: Diagrams Exhaust System-Exploded View Tires - Vibration Highway at Speeds Tires: All Technical Service Bulletins Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 45 P0108 Page 5026 P1450 P1450 Service and Repair Body Control Module: Service and Repair SMART JUNCTION BOX (SJB) Removal and Installation 1. CAUTION: Prior to removal of the SJB, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery. 2. Remove the floor console SJB cover. 3. Remove the transmission selector lever bezel from the floor console finish panel. 4. Apply the parking brake. 5. Remove the parking brake lever boot from the floor console finish panel. 6. Remove the floor console finish panel. Page 7684 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 5878 2. NOTE: Mark the hood latch position prior to removal of the bolts. Position the hood latch assembly aside. 1 Loosen the hood latch nut. 2 Remove the hood latch bolts. 3 Position the hood latch aside. 3. Detach the wiring harness pin-type retainers. 4. Remove the radiator support bracket bolt. 5. Remove the front impact severity sensor bolt. 6. Disconnect the electrical connector and remove the front impact severity sensor. Installation 1. Connect the electrical connector to the front impact severity sensor. 2. NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and free of foreign material. Align the locator tabs of the front impact severity sensor to the openings in the radiator support bracket. 3. WARNING: The tightening torque of the air bag front impact severity sensor retaining bolt is critical for correct system operation. Install the front impact severity sensor bolt. Tighten to 12 Nm (9 lb-ft). 4. Install the radiator support bracket bolt. - Tighten to 12 Nm (9 lb-ft). 5. Attach the wiring harness pin-type retainers. Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Page 2005 Fuse Block: Application and ID Battery Junction Box Page 6512 Page 5095 Alignment: Specifications General Specifications Page 7158 4. Disconnect the speed control cable from the speed control actuator pulley. 1. Gently push the retaining spring. 2. Disconnect the speed control cable slug from the speed control actuator pulley. Installation 1. 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. CAUTION: - It is necessary to squarely seat the speed control cable cap and seal around the speed control actuator pulley. - Incorrect wrapping of the speed control cable around the speed control actuator pulley may result in high idle conditions. NOTE: Make sure the rubber seal is fully seated onto the speed control cable cap. Align the speed control cable cap tabs with the slots in the speed control actuator housing. Description and Operation Air Bag Resistor: Description and Operation Driver 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 driver seat side air bag bridge resistor: is located beneath the driver seat. - is equipped only on Escape Hybrid, Mariner and late build Escape vehicles that are not equipped with seat side air bag modules. Passenger 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 passenger seat side air bag bridge resistor: is located beneath the passenger seat. - is equipped only on Escape Hybrid, Mariner and late build Escape vehicles that are not equipped with seat side air bag modules. Safety Canopy Bridge Resistor CAUTION: Do not deactivate the safety canopy module circuit or seat side air bag module circuit by removing the bridge resistor from the electrical connector. If the safety canopy or 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 safety canopy or seat side air bag electrical connector, a low-resistance fault will be generated. NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. The safety canopy bridge resistor: is equipped on vehicles without safety canopy modules. - must not be removed during deactivation. - is attached to the headliner near the LH D-pillar. Page 4989 Multiple Junction Connector: Diagrams C312-C422 Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Page 7647 Special Tool(s) Page 7614 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 7086 Page 2980 Symbols Part 3 Page 3135 Crankshaft Position Sensor: Diagrams Steering - Improved Drift/Pull Diagnostics Alignment: All Technical Service Bulletins Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Page 6809 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Page 2985 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 6537 Escape Is Shown, Mariner Is Similar (Part 2) Removal and Installation CAUTION: - Prior to removal of the front bumper cover, place tape at the corners of the bumper cover and below the headlamps to prevent damage to the paint. - On Mariner vehicles, when removing and installing the rear bumper cover, carefully remove the RH outer bumper cover mount around the exhaust pipe to avoid breaking the RH outer bumper cover mount. 1. Remove the 2 rear bumper cover-to-splash shield bolts (1 each side). - To install, tighten to 8 Nm (71 lb in). 2. CAUTION: When removing the outer rear bumper cover pin-type retainers, use caution to prevent breaking the outer rear bumper cover mounts. Remove the 2 center and 2 outer rear bumper cover pin-type retainers. 3. Remove the 6 rear bumper cover screws. 4. Remove the 2 liftgate alignment bumper bolts and the 2 liftgate alignment bumpers. - To install, tighten to 8 Nm (71 lb-in). 5. If equipped, disconnect the parking aid system electrical connector. 6. Remove the rear bumper cover. 7. To install, reverse the removal procedure. - When installing, position the rear bumper cover into the bumper slides. Page 2636 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. Diagrams Page 6996 18. Position the seat position sensor interrupt bracket, then install the two bolts. 19. Position the electrical connector bracket and install the two bolts. 20. Position the seat track in the vehicle. - The left and right front mounting feet holes should align with the floor pan mounting holes, without pushing or pulling the seat track to force alignment. Check the witness marks (indentations) in the carpet. The tracks should line up closely with them. - If the seat track does not align to the vehicle, check to make sure the index marks on the inboard and outboard track rails and guides are still in alignment. Repeat the necessary steps until the index marks align. 21. Install the seat track. 22. Install the seat and repower the SRS. Page 4363 1. Inspect the condition of the transfer case vent hole. ^ By hand, insert the new transfer case vent into the transfer case cover and measure the distance between the transfer case cover and the vent as indicated. ^ If the measurement is less than specification, install a new transfer case. 2. CAUTION: Do not apply silicone sealant to the transfer case vent hole as it may cause damage to the transfer case internal components. Apply a bead of silicone gasket and sealant to the transfer case vent where indicated. 3. NOTE: Drive the transfer case vent in until the special tool bottoms out against the transfer case rear cover boss. Using the special tool, install the transfer case vent. 4. Measure the depth of the transfer case vent. Seat Pressure Sensor Locations View 151-7 (Engine, front) Page 327 P0507 Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 586 P1388 Page 7040 View 151-21 (Passenger Seat) Locations View 151-7 (Engine, front) Restraints - Control Module DTCs & Associated Fault PIDs Air Bag 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 7510 Interior Lamp C931 Liftgate Ajar Switch C478 Page 3533 Inertia Fuel Shutoff Switch: Description and Operation Inertia Fuel Shutoff (IFS) Switch Inertia Fuel Shutoff (IFS) Switch The inertia fuel shutoff (IFS) switch is used in conjunction with the electric fuel pump. The purpose of the IES switch is to shutoff the fuel pump if a collision occurs. It consists of a steel ball held in place by a magnet. When a sharp impact occurs the ball breaks loose from the magnet rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the switch and shuts off the electric fuel pump. Once the switch is open it must be manually reset before restarting the vehicle. Refer to the Owner's Literature for the location of the IFS. Fuel Rail Pressure (FRP) Sensor Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure (FRP) Sensor FUEL RAIL PRESSURE (FRP) SENSOR Fuel Rail Pressure (FRP) Sensor The FRP sensor is a diaphragm strain gauge device in which resistance changes with pressure. The electrical resistance of a strain gauge increases as pressure increases, and the resistance decreases as the pressure decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to pressure. Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a voltage divider network so that varying the resistance of the passive sensor causes a variation in total current flow. Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage drop across the fixed resistor. The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder. Page 7679 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 3696 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 7482 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. Seat Belt Buckle Sensor Seat Sensor/Switch: Diagrams Seat Belt Buckle Sensor Page 7443 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 Locations Diagrams Page 7483 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 3062 4. NOTE: If necessary, lubricate the sensor threads with penetrating and lock lubricant to assist in removal. Using the special tool, remove the HO2S. To install, tighten to 48 Nm (35 lb-ft). 5. NOTE: Apply a light coat of anti-seize lubricant to the threads of the heated oxygen sensor. To install, reverse the removal procedure. Page 2558 2. NOTE: If installing a new dual converter Y-pipe, remove the catalyst monitor sensor for installation in the new dual converter Y-pipe. NOTE: Apply anti-seize lubricant to the threads of the catalyst monitor before installation. Using the special tool, disconnect the RH catalyst monitor sensor. ^ To install, tighten to 47 Nm (35 ft. lbs.). 3. CAUTION: Do not allow the dual converter Y-pipe to hang from the flexible end. Support the dual converter Y-pipe. Remove and discard the 2 exhaust catalytic converter nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Remove and discard the exhaust hanger from the Y-pipe. 5. Remove and discard the 4 dual converter Y-pipe nuts and remove the Y-pipe. ^ To install, tighten to 47 Nm (35 ft. lbs.). 6. To install, reverse the removal procedure. ^ Install new dual converter Y-pipe gaskets. P0276 P0276 Page 2491 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. System Diagnosis P1244 Component Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 895 Page 2879 The IAT provides air temperature information to the PCM. The PCM uses the air temperature information as a correction factor in the calculation of fuel, spark, and air flow. The IAT sensor provides a quicker temperature change response time than the ECT or CHT sensor. Currently there are 2 design types of AT sensors used, a stand-alone/non-integrated type and a integrated type. Both types function the same, however the integrated type is incorporated into the mass air flow (MAF) sensor instead of being a stand alone sensor. Supercharged vehicles use 2 IAT sensors. Both sensors are thermistor type devices and operate as described above. However, one is located before the supercharger at the air cleaner for standard OBD/cold weather input, while a second sensor (IAT2) is located after the supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air temperature information to the PCM to control border-line spark and to help determine intercooler efficiency. Compass Zone Adjustment Compass: Adjustments Compass Zone Adjustment COMPASS ZONE ADJUSTMENT 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 switch to the ON position. 3. Press the message center switch INFO button until the compass information is displayed in the message center. 4. Press the RESET and SETUP button simultaneously 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. 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. Service and Repair Ignition Lock: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 3894 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 2479 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 3669 Page 5027 Engine Crankshaft - Pulley Bolt Service Precautions Harmonic Balancer - Crankshaft Pulley: Technical Service Bulletins Engine Crankshaft - Pulley Bolt Service Precautions TSB 06-21-4 10/30/06 2.3L/2.0L DURATEC - NO START/POSSIBLE ENGINE DAMAGE - INSTALL SPECIAL SERVICE TOOLS PRIOR TO REMOVING CRANKSHAFT PULLEY BOLT FORD: 2003-2007 Focus 2006-2007 Fusion 2001-2007 Ranger 2005-2007 Escape Hybrid, Escape MERCURY: 2006-2007 Milan 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 06-16-6 to include symptoms, labor operations, and parts. ISSUE Some 2001-2007 MY vehicles equipped with a 2.0L or 2.3L Duratec Engine may exhibit no start, loss of engine timing or scraping noise at crankshaft pulley at front of engine. These engines, (excludes 2.0L SPI and Zetec engines) may experience engine damage if the crankshaft pulley bolt is loosened during service WITHOUT FIRST INSTALLING THE SPECIAL SERVICE TOOLS PER THE WORKSHOP MANUAL PROCEDURE. The crankshaft pulley bolt also retains the crankshaft cam drive sprocket which is NOT keyed to the crankshaft, so valve timing may shift if the crankshaft pulley bolt is loosened. If this occurs, the pistons may contact and damage the valves. ACTION Before ANY repair requiring loosening or removal of the crankshafl pulley bolt, engine valve timing MUST be locked by the Special Service Tools identified in the online Workshop Manual, Section 303-01 (In-Vehicle Repair: Crankshaft Pulley). Do not attempt to start the engine without verifying engine cam timing. SERVICE PROCEDURE CAUTION FAILURE TO FOLLOW THE PROCEDURE EXACTLY CAN RESULT IN SERIOUS ENGINE DAMAGE. SERVICE TOOLS REQUIRED ARE: 1. Crankshaft Timing Peg ESST Number 303-507 is 2-1/8" (54 mm). 2. Camshaft Alignment Plate ESST Number 303-465. 3. Holding Fixture ESST Number 205-126. 4. Adaptor 205-072-02. Page 4279 2. Connect the select cable. 3. Connect the gearshift cable. 4. CAUTION: Make sure the clips are set completely within the cable adapter groove and fully seated. Install the 2 gearshift cable clips. 5. Install the 4 gearshift lever bolts. ^ Tighten to 20 Nm (15 ft. lbs.). 6. Adjust the gearshift cables. 7. Install the floor console. Page 775 P2071 Page 3827 3. NOTE: Some vehicles are equipped with a cold weather bypass valve which cannot by cleaned or flushed. A new valve should be installed as part of an overhaul or prior to the installation of a remanufactured transaxle. Using compressed air, blow through the coolers until all fluid is removed. Page 7224 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 Specifications Brake Fluid: Specifications Brake Fluid Type .......................................................................................... Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 Locations View 151-8 (Engine, rear) Page 4842 Page 4857 Power Distribution Relay: Testing and Inspection Page 6963 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 1001 Testing and Inspection Micro ISO Relay: Testing and Inspection Page 5365 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 3243 Throttle Position Sensor: Diagrams Page 3532 Page 4037 Clutch Disc: Service and Repair Clutch Disc and Pressure Plate Special Tool(s) Page 5200 14. NOTE: Install a new high pressure hose O-ring seal and a new return hose O-ring seal. Remove the power steering pressure and return lines. 15. Remove the 2 steering gear mounting bolts. ^ To install, tighten to 126 Nm (93 ft. lbs.). 16. NOTE: Remove the steering gear from the RH side of the vehicle. Remove the steering gear. 17. To install, reverse the removal procedure. 18. Fill the power steering system. 19. Check and, if necessary, align the front end. B-Pillar Trim Panel Trim Panel: Service and Repair B-Pillar Trim Panel B-PILLAR TRIM PANEL Removal and Installation 1. NOTE: Inspect the safety belt D-ring cover for damage. If the safety belt D-ring cover does not remain in place, install a new cover. Remove the safety belt D-ring cover and remove the safety belt bolt. To install, tighten to 53 Nm (39 lb-ft). 2. Position the front and rear door weatherstrips aside. 3. Remove the cover, bolt and the upper B-pillar trim panel. - To install, tighten to 7 Nm (62 lb-in). 4. Remove the 2 pin-type retainers and the front door scuff plate trim panel. 5. Remove the pin-type retainer and the rear door scuff plate trim panel. 6. Remove the lower B-pillar trim panel. 7. To install, reverse the removal procedure. Page 4813 Page 6812 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 5170 Power Steering Pressure Switch: Diagrams Page 6063 Page 6233 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 1097 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 3287 Catalytic Converter: Service and Repair Catalytic Converter Catalytic Converter Removal and Installation NOTE: Do not use oil or grease-based lubricants on the insulators. They may cause deterioration of the rubber. NOTE: Oil or grease-based lubricants on the insulators may cause the exhaust hanger insulator to separate from the exhaust hanger bracket during vehicle operation. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove and discard the 2 exhaust catalytic converter nuts. ^ To install tighten to 47 Nm (35 ft. lbs.). 3. Remove and discard the U-bolt clamp assembly from the muffler. ^ To install, tighten to 47 Nm (35 ft. lbs.). 4. Remove and discard the 2 resonator nuts. ^ To install, tighten to 47 Nm (35 ft. lbs.). 5. Remove and discard the catalytic converter exhaust hanger. 6. Remove the exhaust catalytic converter and the muffler from the vehicle as an assembly. 7. Separate the converter from the muffler. 8. To install, reverse the removal procedure. ^ Install new gaskets. Page 4038 Removal 1. Remove the transaxle. 2. Using the special tool, lock the flywheel to the engine. Page 4549 6. CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the piston. NOTE: Inspect the brake caliper piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new caliper must be installed. Remove the brake caliper piston. 1. Place a block of wood between the brake caliper piston and the brake caliper housing. 2. Apply compressed air through the brake caliper jounce hose port to remove the piston. 7. Remove the dust boot. 8. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. Remove the piston seal using a plastic or wooden tool. 9. To assemble, reverse the disassembly procedure. ^ Lubricate the piston seal with clean brake fluid. Page 4620 Brake Caliper: Service and Repair Brake Caliper Anchor Plate, Front Brake Caliper Anchor Plate Removal and Installation 1. Remove the brake pads. 2. Remove the 2 brake caliper anchor plate bolts. ^ To install, tighten to 150 Nm (111 ft. lbs.). 3. Remove the brake caliper anchor plate. 4. To install, reverse the removal procedure. Page 1270 Page 7196 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 1764 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 5 compression strokes and record the highest reading. Note the approximate number of compression strokes necessary to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test-Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. For additional information, refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart If one or more cylinders reads low, squirt approximately one tablespoon of engine oil meeting Ford specification on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test-Interpreting Compression Readings 1. If compression improves considerably, piston rings are worn or damaged. Page 1980 Fuse: Locations Battery Junction Box Page 4015 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Locations View 151-12 (Dash Panel) Page 4592 Brake Drum: Diagrams Page 10 P0012 Page 1386 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Locations View 151-20 (Driver Seat) Page 7079 Power Door Lock Switch: Testing and Inspection Master Window/Door Lock/Unlock Switch Page 1405 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater by providing the ground when the proper conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Page 7670 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 3115 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 5911 2. 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. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure. - 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. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCS ECU into the seat cushion pan bracket and install the rivets. - The OCS 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). 7. Position the foam pad to the seat cushion pan. 8. 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. Install seat cushion trim cover to seat cushion foam pad and attach the J-clips. 9. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 10. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). Page 4337 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. System Diagnosis P0345 Description and Operation Catalytic Converter: Description and Operation Catalyst and Exhaust Systems Overview The catalytic converter and exhaust systems work together to control the release of harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of nitrogen carbon dioxide (C02) and water vapor (H20). However~ it also contains carbon monoxide (CO) oxides of nitrogen (NO) hydrogen (H) and various unburned hydrocarbons (HCs). CO NO 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. For information on the OBD catalyst monitor refer to the description for the Catalyst Efficiency Monitor in this section. The number of HO2S used in the exhaust stream and the location of these sensors depend on the vehicle emission certification level (i.e. LEV ULEV PZEV). On most vehicles only 2 HO2S are used in an exhaust stream. The front sensors (HO2S1 1/H02S21) before the catalyst will be used for primary fuel control while the ones afier the catalyst (H02S12/H02S22) will be used to monitor catalyst efficiency. However some partial zero emission vehicles (PZEV) will use 3 HO2S sensors for each engine bank. The stream 1 sensors (HO2S1 1/H02S21) located before the catalyst are used for primary fuel control the stream 2 sensors (H02S12/H02S22) are used to monitor the light-off catalyst and the stream 3 sensors (H02S13/H02S23) located afier the catalyst are used for long term fuel trim control to optimize catalyst efficiency (fore afi oxygen sensor control). Current PZEV vehicles use only a 4-cylinder engine so only the Bank 1 HO2S will be used. 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 246°C to 301°C (475°F to 575°F). A fast light catalyst is a 3-way catalyst (TWC) that is located as close to the exhaust Specifications Firing Order: Specifications Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 6843 OASIS ACTIVATED? Yes. OASIS was activated April 5, 2006. FSA VIN LIST ACTIVATED? Yes. FSA VIN lists will be available through the website by May 15, 2006. Owner names and addresses will be available by May 26, 2006. 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 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. If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center. OWNER REFUNDS Refunds are not authorized for this program. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using Direct Warranty Entry (DWE). ^ 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 the Special Service Support Center. ^ "MT" labor must be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from the Special Service Support Center. ^ Refer to ACESII manual for claims preparation and submission information. Page 3582 Page 2803 Camshaft Position Sensor: Diagrams Page 7657 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Seat Belt Buckle Sensor Seat Sensor/Switch: Diagrams Seat Belt Buckle Sensor Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 4563 Brake Pad: Specifications Front Brake Pad Minimum Thickness ............................................................................................................................. ............................................ 3.0 mm (0.118 inch) Rear Brake Pad Minimum Thickness ............................................................................................................................. ............................................ 3.0 mm (0.118 inch) Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Page 2478 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 5751 Blower Motor Relay: Testing and Inspection Service and Repair Vacuum Harness HVAC: Service and Repair VACUUM HOSE REPAIR Vacuum Pump Kit Special Tool(s) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8-inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. WARNING: Read the warning information on the product label to prevent possible personal injury. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8-inch repair vacuum hose section. 6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use a vacuum pump. Service and Repair Quarter Window Glass: Service and Repair REAR QUARTER WINDOW GLASS Interior Auto Glass Cut-Out Knife Kit Special Tool(s) Removal WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. Failure to follow these instructions may result in personal injury. LH Rear Quarter Window Glass 1. If equipped, remove the auxiliary climate control housing. 2. If equipped, remove the bolt and the auxiliary climate control upper housing bracket. All Rear Quarter Window Glass 3. Remove the headliner. Page 3031 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Page 7211 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 4922 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 977 Page 2986 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 5398 Toe-In Can Be Claimed With Operation B And C (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) DEALER CODING CONDITION BASIC PART NO. CODE 18A179 07 Disclaimer Page 6806 22. From under the rear of the passenger seat, slide and disengage the passenger seat side air bag module electrical connector locking clip, and then release the tab and disconnect the passenger seat side air bag module electrical connector. 23. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger seat side air bag module electrical connector. 24. From under the rear of the driver seat, slide and disengage the driver seat side air bag module electrical connector locking clip, and then release the tab and disconnect the driver seat side air bag module electrical connector. 25. Attach the restraint system diagnostic tool to the vehicle harness side of the driver seat side air bag module electrical connector. All vehicles 26. Install the RCM fuse F33 (15A) to the SJB. 27. Connect the battery ground cable. Page 6785 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 7889 Power Window Switch: Diagrams Window Adjust Switch Page 1702 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Screen and Pickup Tube Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the oil pan. 3. NOTE: Discard the gasket and clean and inspect the gasket mating surfaces. Remove the 2 bolts and the oil pump screen and pickup tube. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. To install, reverse the removal procedure. Page 59 P0119 Page 3413 Page 3553 Page 211 P0300 Page 6713 Part 1 Locations View 151-14 (Under Dash Panel, LH Side) Page 6296 Special Tool(s) Page 7234 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 7728 View 151-11 (Manual Transmission) Service and Repair Windshield Washer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 6241 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 876 Seat Heater Control Module: Service and Repair HEATED SEAT MODULE Removal and Installation WARNING: - Never probe the connectors on the air bag module or pretensioner. Doing so may result in pretensioner or air bag deployment and may result in personal injury. Failure to follow these instructions may 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 may result in pretensioner or air bag deployment. Failure to follow these instructions may 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 air bag or side air curtain supplemental restraint system (SRS) components and before repairing, replacing, adjusting or striking components near the front air bag or side air curtain sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. Refer to the appropriate Component or System to determine the location of the front air bag sensors. Page 2159 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 the 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 2 halves couple the camshaft to the timing chain. When the flow of oil is shifted from one side of the chamber to the other, the differential change in oil pressure forces the camshaft to rotate in either a advance or retard position depending on the oil flow. Page 6578 BASIC PART NO. CODE 78237A05 12 Disclaimer P0703 P0700 - P0704: Testing and Inspection P0703 P0703 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 Page 2317 LH Transmission Mount: Service and Repair LH Transaxle Support Insulator-LH Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the air cleaner. Page 7500 Courtesy Lamp: Connector Views Page 7914 View 151-24 (Rear Door (RH Side Shown, LH Side Similar)) Page 7644 A8-A9 Normal Operation The horn relay B+ power is supplied through circuit 1682 (RD/LB). The horn relay is controlled by the horn switch. The horn relay is grounded through the horn switches by circuit 6 (YE/LG). When the horn switch is pressed, the horn relay control circuit 6 (YE/LG) is grounded through circuit 57 (BK). The relay is then closed causing B+ voltage to be applied to circuit 1 (DB), sounding the horns. Possible Causes - circuit 1 (DB) open - circuit 6 (YE/LG) open - circuit 57 (BK) open - circuit 1682 (RD/LB) open - clockspring - horn relay - horn - horn switch - SJB Test B: The Horn Is Always On PINPOINT TEST B: THE HORN IS ALWAYS ON B1 Page 7662 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. Page 5472 3. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. Diagrams Page 3702 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 2900 Clutch Switch: Service and Repair CLUTCH PEDAL POSITION (CPP) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the clutch pedal position (CPP) switch electrical connector. 3. Rotate the CPP switch clockwise and remove the CPP switch. 4. To install, reverse the removal procedure. Page 1933 1. Check for leaks using an approved UV lamp. - Inspect all the 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 an approved UV lamp. Fluorescent Dye Injection - Using an A/C 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 an 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. New 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 manufacturer 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 refrigerant 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. - The 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 center or a manifold and gauge set to the refrigerant system port valves. 2. Verify that the valves on the fluorescent dye injector are closed. Locations View 151-8 (Engine, rear) Page 7575 Page 8004 Windshield Washer Reservoir: Service and Repair Windshield Washer Pump and Reservoir WINDSHIELD WASHER PUMP AND RESERVOIR Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. Disconnect the windshield and rear window washer pump electrical connectors. 4. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before removal. Disconnect the front and rear washer pump hoses. 5. Remove the 2 windshield washer reservoir bolts and the windshield washer reservoir. - To install, tighten to 6 Nm (53 lb-in). 6. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: Do not operate the windshield or rear window washer pumps prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Page 7805 Symbols Part 2 Page 7404 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. Page 1981 P1235 P1235 Page 6142 Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Service Kit OCCUPANT CLASSIFICATION SENSOR - SERVICE KIT Worldwide Diagnostic System (WDS) Special Tool(s) 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. Component Locations Smart Junction Box Fuse Block: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 3895 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 A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 1820 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the RH splash shield. 4. If equipped, disconnect the engine block heater electrical connector. 5. Disconnect the A/C compressor electrical connector. 6. Remove the suction accumulator to compressor line bolt. - To install, tighten to 20 Nm (15 lb-ft). 7. Disconnect the suction accumulator to compressor line from the A/C compressor. 8. Remove the 2 suction accumulator to compressor line bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 9. Disconnect the suction accumulator to compressor line spring lock coupling. 10. Remove the suction accumulator to compressor line. 11. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 7999 Windshield Washer Pump: Service and Repair Rear Window Washer Pump REAR WINDOW WASHER PUMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: When replacing the rear window washer pump, be careful not to damage the rubber grommet. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Remove the rear window washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the rear window washer pump. 4. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. Page 5337 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 4673 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. Page 5474 Special Tool(s) Removal NOTE: LH is shown, RH is similar. 4WD vehicles 1. Remove the wheel knuckle. FWD vehicles 2. Remove and discard the wheel hub nut. 3. Remove the Anti-Lock Brake System (ABS) wheel speed sensor ring. All vehicles Page 1824 11. Remove the A/C compressor manifold and tube assembly. - Remove and discard the O-rings. 12. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 1369 Fuel Pressure Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Page 5790 10. Open the glove compartment door past its stops. 11. Through the glove compartment opening, disconnect the passenger air bag module electrical connector. Escape and Mariner vehicles 12. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Escape Hybrid vehicles 13. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag module electrical connector. Vehicles without safety canopies Page 6700 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 5390 C. Apply Motorcraft Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust boot. (3) Apply 360 degrees to the jounce bumper itself. d. Assemble front strut and install per WSM, Section 204-01. e. Repeat the procedure on the other side of the vehicle. 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 090605A 2001-2009 Escape, 0.7 Hr. 2005-2009 Escape Hybrid, Mariner 2006-2009 Mariner Hybrid: Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test (Do Not Use With 1007D, 18124A) 090605B 2001-2009 Escape, 1.5 Hrs. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Replace The Strut Dust Boots, Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test Can Be Claimed With Operations C And D (Do Not Use With 1007D, 18124A) 090605C 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Check Caster, Camber and, Toe-In Can Be Claimed With Operation B And D (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090605D 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Correct Caster, Camber And Page 4146 journal with fine crocus cloth. Install the halfshaft assembly. Diagrams Page 7462 L2-L8 Page 1672 Page 7294 Symptom Chart (Part 4) Locations View 151-7 (Engine, front) Page 7206 Audible Warning Device: 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 5137 Removal and Installation CAUTION: While 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. Drain the power steering fluid into a suitable drain pan. 2. Remove the 2 power steering pump reservoir bolts. ^ To install, tighten to 8 Nm (71 inch lbs.) 3. Release the clamp and disconnect the power steering fluid cooler-to-fluid reservoir hose. 4. Release the clamp and disconnect the power steering suction hose. 5. Remove the power steering pump reservoir. 6. To install, reverse the removal procedure. ^ Fill the power steering system. Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE 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. 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 1 key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine. 7. Start the vehicle and check the fuel system for leaks. Page 4273 2. NOTE: Both gearshift cables disconnect from the transmission in the same manner. Disconnect the gearshift cables from the transmission. 1 Lift the gearshift cables out of the cable bracket. 2 Disconnect the gearshift cables from the transaxle gearshift control assembly. 3 Remove the 2 gearshift cable clips. 3. Remove the 2 gearshift cable clips. 4. Disconnect the 2 gearshift cables from the gearshift lever. 5. Remove the 2 gearshift cable grommet nuts. 6. Remove the gearshift cables. Installation 1. CAUTION: When inserting the gearshift cables through the dash panel, make sure the arrow on the grommet is pointing down. Insert the gearshift cables through the dash panel. 2. Connect the select cable. Front Page 3152 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Page 6990 16. Remove the two bolts holding the seat track motor assembly to the outboard track. 17. NOTE: The pinion cage will be removed with the outboard track. Carefully pry between the seat track motor assembly and the outboard track and remove the outboard track. 18. Carefully pry and remove the two support straps. 19. Pry and remove the seat track motor assembly from the upper support assembly. Installation Page 7924 Power Window Switch: Testing and Inspection Window Adjust Switch Page 4527 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Rear Wheel Speed Sensor Ring-Rear Removal and Installation FWD vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel hub nut. ^ To install, tighten to 290 Nm (214 ft. lbs.). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. 4WD vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. P2005 P2005 Page 6938 Tape/Paint Stripe Tape and paint stripe codes do not apply. Service and Repair Evaporative Emissions Hose: Service and Repair FUEL VAPOR CONTROL TUBE ASSEMBLY VALVE Disconnect Tool, Fuel Pipe Special Tool(s) 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. Driver Side View 151-20 (Driver Seat) Page 6807 Reactivation All vehicles 1. Remove the RCM fuse F33 (15A) from the SJB. 2. Disconnect the battery ground cable and wait at least one minute. Escape Hybrid, Mariner and late build Escape vehicles with 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. 4. Connect the driver seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. 5. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger seat side air bag module electrical connector. Description and Operation Accelerator Pedal Position Sensor: Description and Operation ACCELERATOR PEDAL POSITION (APP) SENSOR For information on the APP sensor, refer to the description for Torque Based Electronic Throttle Control (ETC). Seat Pressure Sensor View 151-21 (Passenger Seat) Page 2967 Idle Speed/Throttle Actuator - Electronic: Description and Operation IDLE AIR CONTROL (IAC) VALVE (APPLICATIONS WITHOUT ETC) The IAC valve assembly controls the engine idle speed and provides a dashpot function. The IAC valve assembly meters intake air around the throttle plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle. The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The PCM monitors engine RPM and increases or decreases the IAC duty cycle in order to achieve the desired RPM. NOTE: The IAC valve assembly is NOT ADJUSTABLE and CANNOT BE CLEANED, also some IAC valves are normally open and others are normally closed. Some IAC valves require engine vacuum to operate. The PCM uses the IAC valve assembly to control: - No touch start. - Cold engine fast idle for rapid warm-up. - Idle (corrects for engine load). - Stumble or stalling on deceleration (provides a dashpot function). - Over-temperature idle boost. Page 1783 Cabin Air Filter: Service and Repair CABIN AIR FILTER Removal and Installation 1. Remove the RH cowl panel grille. 2. Remove the 2 water shield screws and the water shield. 3. Remove the cabin air filter. 4. To install, reverse the removal procedure. Description and Operation Seat Belt Buckle Switch: Description and Operation SAFETY BELT BUCKLE SWITCHES As part of the supplemental restraint system (SRS), the front safety belt buckles are equipped with safety belt buckle switches. The safety belt buckle switches are comprised of integrated circuits called Hall-effect sensors. The safety belt buckle switches (Hall-effect sensors) are located in the driver and passenger safety belt buckles. The safety belt buckle switches indicate to the restraints control module (RCM) whether the safety belts are connected or disconnected. The RCM uses this information in determining the deployment rate of the dual-stage driver and passenger air bag modules. The RCM also communicates the driver safety belt buckle switch status to the instrument cluster module, which monitors the information to control the safety belt warning indicator. A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Locations View 151-13 (Behind Dash Panel) Page 3874 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 2176 Crankshaft: Specifications Crankshaft Main bearing journal diameter ................................................................................................................................. 51.980-52.000 min (2.046-2.047 in.) Page 5962 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 7330 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Locations View 151-8 (Engine, rear) Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Page 1265 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. Page 3016 H6-H8 Page 2920 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts). - 2 signal return (ground) circuits. - APP1 voltage with negative voltage slope (5-0 volts). - APP2 voltage with positive voltage slope (0-5 volts). - APP3 voltage with positive voltage slope (0-5 volts). 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a fault. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value will be substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Page 2983 Information Bus: 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 4548 Brake Caliper: Service and Repair Caliper Disassembly and Assembly, Rear Brake Caliper Material Material 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 the surface with water Disassembly and Assembly 1. Remove the brake caliper. 2. Secure the brake caliper in a vise. 3. Remove the brake caliper dust boot. 4. Remove the bleeder screw cap. 5. Remove the bleeder screw. ^ To install, tighten to 16 Nm (12 ft. lbs.). Page 4415 Seals and Gaskets: Service and Repair Transfer Case Inner Halfshaft Seal Transfer Case Inner Halfshaft Seal Special Tool(s) Removal 1. Remove the transfer case. 2. Using the special tools, remove the transfer case inner halfshaft seal. Installation Page 7558 Locations View 151-14 (Under Dash Panel, LH Side) Page 4699 Parking Brake Warning Switch: Service and Repair Parking Brake Warning Indicator Switch Removal and Installation 1. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 2. Remove the warning indicator switch screw. 3. Disconnect the warning indicator switch electrical connector. 4. Remove the warning indicator switch. 5. To install, reverse the removal procedure. System Diagnosis P0657 Page 6283 Symptom Chart (Part 3) Page 83 P0138 Service and Repair Turn Signal Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After A Supplemental Restraint System (SRS) Deployment Inspection and Repair After a Supplemental Restraint System (SRS) Deployment WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to follow this instruction may result in serious personal injury or death in a crash and possibly violate vehicle safety standards. NOTE: After diagnosing or repairing a supplemental restraint system (SRS), the restraint system diagnostic tools (if required) must be removed before operating the vehicle over the road. NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various combinations depending on the impact event. NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs affecting the SRS and safety belt system. NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer. All vehicles 1. NOTE: Refer to the correct removal and installation procedure for all SRS components being installed. When any deployable device or combination of devices are deployed and/or the restraints control module (RCM) has the DTC B1231 (Event Threshold Exceeded) in memory, the repair of the vehicle's SRS is to include the removal of all deployed devices and the installation of new deployable devices, the removal and installation of new impact sensors, and the removal and installation of a new RCM. DTCs must cleared from all required modules after repairs are carried out. Vehicles with occupant classification sensor (OCS) system 2. NOTE: After installation of new occupant classification sensor (OCS) system components carry out the OCS System Reset procedure as instructed in the workshop manual. Refer to the appropriate workshop manual for OCS system removal and installation procedure. When a vehicle has been involved in a collision and the occupant classification system module (OCSM) has DTC B1231 stored in memory, the repair of the OCS system is to include the following procedures for the specified system: - For rail type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install new OCS system rails. - For weight sensor bolt type OCS system, inspect the passenger side floorpan for damage and repair as necessary. Install a new seat track with OCS system weight sensor bolts. DTC must be cleared from the OCSM before carrying out Occupant Classification Sensor (OCS) System Reset. Do not install a new OCSM unless DTC B1231 cannot be cleared. - NOTE: Most bladder type OCSM do not store a DTC B1231 in memory after deployment. The DTC B1231 is stored only by the RCM. For bladder type OCS system, inspect for damage and repair as necessary. If installation of an OCS system component is required, an OCS system service kit must be installed. All vehicles 3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. 4. When the driver air bag module has deployed, a new clockspring must be installed. 5. New driver and/or front passenger safety belt systems (including retractors, buckles and height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of the driver and/or front passenger safety belt pretensioners. For additional information, refer to Safety Belt System. 6. Inspect the entire vehicle for damage, including the following components: Steering column (deployable column if equipped) Instrument panel knee bolsters and mounting points Instrument panel braces and brackets Instrument panel and mounting points Seats and seat mounting points Safety belts, safety belt buckles and safety belt retractors. Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 3475 Exploded View Component Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Master Window/Door Lock/Unlock Switch Page 5039 Page 4241 Flywheel: Diagrams Lower End Components-Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Page 1402 P0196 P0196 Page 4756 Alternator: Description and Operation GENERATOR The charging system consists of the following components: - generator - integral voltage regulator The generator maximum output provides 120 amps. Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 321 P0503 Page 5565 Using the special tools, install the A/C clutch field coil. 3. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. Install the A/C clutch pulley. 4. Install the A/C clutch pulley snap ring with the bevel side out. 5. Place 1 nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch disc and hub assembly. Page 5069 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 5556 Cabin Air Filter: Service and Repair CABIN AIR FILTER Removal and Installation 1. Remove the RH cowl panel grille. 2. Remove the 2 water shield screws and the water shield. 3. Remove the cabin air filter. 4. To install, reverse the removal procedure. Liftgate Ajar Switch Locations Fluid Filter - A/T: Locations Part 1 Of 7 Transmission Fluid Filter Location Filter is located at exploded view position number 8 internal. See Transmission Disassembly/Assembly. Locations Page 7886 View 151-22 (Left Front Door) Page 1350 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Page 4502 Page 5498 Air Door Actuator / Motor: Service and Repair Recirculation Blend Door Actuator RECIRCULATION BLEND DOOR ACTUATOR Removal and Installation 1. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 2. Disconnect the recirculation vacuum control motor vacuum supply hose. 3. Remove the 2 recirculation vacuum control motor screws. 4. Rotate the vacuum control motor until it clears the retaining arm and remove the vacuum control motor. 5. To install, reverse the removal procedure. Page 6461 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 3979 7. Disconnect and remove the fluid cooler tube bracket from the transaxle case. ^ To install, tighten to 25 Nm (18 ft. lbs.). 8. Fill the transaxle with clean automatic transmission fluid. 9. Remove the fluid cooler tubes from under the vehicle and install new as necessary. 10. To install, reverse the removal procedure. Page 6290 C3-C4 P0455 P0455 Auxiliary Temperature Blend Door Actuator Air Door Actuator / Motor: Service and Repair Auxiliary Temperature Blend Door Actuator Auxiliary Mode Door Actuator Removal and Installation. Page 6394 Monterey, Five Hundred, Freestyle, Montego DEALER CODING CONDITION BASIC PART NO. CODE 15K859 42 Disclaimer Page 1510 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. System Diagnosis P1572 Page 4821 Page 3292 Canister Purge Control Valve: Description and Operation Evaporative Emission (EVAP) Canister Purge Valve For information on the EVAP canister purge valve, refer to the description of the Evaporative Emission Systems Page 1375 Mechanical Returnless Fuel Pump Module (FPM) Page 497 P1157 Page 4192 9. Install the snap ring on the front drive halfshaft. 10. Install the tripod joint on the front drive halfshaft. 1 Line up the marks on the front drive halfshaft and tripod joint. 2 Install the tripod joint on the front drive halfshaft. 11. Install the snap ring. 12. Lubricate the 3 tripod joint needle bearings with grease. 13. Fill the tripod joint housing with grease. Page 7094 Page 1519 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Page 1013 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 4098 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 6009 Replacement Brake Fluid: Service and Repair Replacement Brake Fluid Replacement WARNING: Use of any other than the approved DOT 3 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 the surface with water. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Do not allow the master cylinder brake fluid to overflow from the reservoir. Brake fluid may damage the high-voltage components. NOTE: Bleeding the HCU is required only when removing or installing the HCU, master cylinder, or opening the lines to the HCU. NOTE: Make sure that the brake fluid level is above the MIN mark. 1. NOTE: Adequate voltage to the HCU module is required during the system bleed. Connect the diagnostic tool. 2. Access the service bleed function. Access the service bleed function on the diagnostic tool and follow the directions. Page 7617 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 2820 Page 7919 Service and Repair Transmission Speed Sensor: Service and Repair Vehicle Speed Sensor (VSS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: The electrical connector and the VSS are accessed from the top of the transaxle. Remove the VSS bolt. 3. Disconnect the electrical connector and remove the VSS. 4. To install, reverse the removal procedure. Page 194 P0279 Page 2401 1. Inspect the spark plugs. 2. Adjust the spark plug gap as necessary. 3. Install the spark plugs. - Tighten to 12 Nm (9 lb-ft). 4. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Install the ignition coils and bolts. Tighten to 10 Nm (89 lb-in). 5. Connect the ignition coil electrical connectors. 6. Connect the battery ground cable. Page 657 P1517 Service and Repair Fuel Filler Hose: Service and Repair FUEL TANK FILLER PIPE Diagrams Page 5716 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ....................................................................... R134a A/T CD4E - Cold Weather Transmission Failure Transmission Cooler: Technical Service Bulletins A/T CD4E - Cold Weather Transmission Failure TSB 09-25-4 12/28/09 CD4E TRANSMISSION FAILURE - REPLACE OR INSTALL TRANSMISSION FLUID COOLER COLD WEATHER BYPASS KIT FORD: 2001-2008 Escape MERCURY: 2001-2008 Mariner This article supersedes TSB 4-14-1 to update the model year coverage, Part List and Service Procedure. ISSUE Some 2001-2008 Escape and Mariner vehicles equipped with a CD4E transmission may experience a transmission failure due to inadequate lube flow during warm up in cold weather. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow the Workshop Manual, Section 307-01 service procedure to repair the transmission. When overhauling or replacing a CD4E transmission, always install a new cold weather transmission fluid bypass kit, even if not previously equipped. Do not flush or back flush existing transmission cooler bypass valve system or cooler tube system. Follow instruction sheets included in the new Cold Weather Transmission Fluid Cooler Bypass Kit. 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 MT092504 Claim Diagnosis And Labor Actual Performed As Actual Time Time DEALER CODING CONDITION BASIC PART NO. CODE 7K177 55 Disclaimer Page 4583 Brake Rotor/Disc: Service and Repair Disc Removal and Installation, Front Brake Disc Removal and Installation 1. Remove the brake caliper anchor plate. 2. Remove the brake disc. 3. To install, reverse the removal procedure. Page 3090 Electronic Throttle Monitor Operation (Part 1) Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Page 6452 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 3931 1. Lightly lubricate the shifter straw with multi-purpose grease, and install it into the shifter bore by pushing straight down. 2. Feed the overdrive cancel switch electrical connector wire harness into the opening in the dash and install the knob. 3. Install the set screw. 4. Connect the overdrive cancel switch electrical connector. 5. Install the top finish panel. Page 769 P2067 Page 806 P2127 Front Page 7468 Door Handle Front Door Exterior Handle: Service and Repair Door Handle EXTERIOR FRONT DOOR HANDLE Removal and Installation 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Loosen the exterior door handle reinforcement screw. 4. Remove the exterior door handle cover. 1 Pull the exterior door handle. 2 The front of the cover must be released prior to removing the cover. 5. Remove the exterior door handle by sliding the handle towards the rear of the vehicle. 6. Remove the 2 exterior door handle seals. 7. To install, reverse the removal procedure. Page 941 Page 3611 Throttle Body: Service and Repair THROTTLE BODY Removal and Installation 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. Disconnect the battery ground cable. 2. Remove the air cleaner outlet pipe. 3. Remove the upper snow shield screw and pin-type retainer. - Remove the upper snow shield. - To install, tighten to 10 Nm (89 lb-in). 4. Detach the accelerator and speed control cables from the throttle body. 5. Disconnect the throttle position sensor electrical connector. 6. Remove the 4 bolts and the throttle body. - Inspect the throttle body gasket and install new as necessary. - To install, tighten to 10 Nm (89 lb-in). 7. To install, reverse the removal procedure. Page 1908 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer P0190 P0190 Tires - Vibration Highway at Speeds Wheels: All Technical Service Bulletins Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 7316 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Service and Repair Console: Service and Repair FLOOR CONSOLE Removal and Installation All Vehicles 1. Position the seats forward and remove the 2 rear bolts. 2. Position the seats rearward and disconnect the battery. 3. Position the parking brake handle to the full-up position. 4. Remove the transmission selector lever bezel. 5. Release the parking brake handle boot from the floor console finish panel. Mariner 6. Remove the floor console top panel. Page 6459 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. Specifications Camshaft Gear/Sprocket: Specifications Camshaft sprocket bolt ........................................................................................................................ ..................................................... 65 Nm (48 ft. lbs.) Page 5974 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Page 1883 Fluid - A/T: Service and Repair Transmission Fluid Cooler Backflushing and Cleaning Transmission Fluid Cooler Backflushing and Cleaning 1. CAUTION: Flush with clean transmission fluid only. Do not use solvents, mineral spirits or water-based cleaners. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Backflush any contaminates out of the oil-to-air cooler by connecting the flushing machine pressure line to number 1 and the return line to number 2. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. 2. Backflush any contaminants out of the radiator in-tank cooler by connecting the flushing machine pressure line to number 2 and the return line to number 3. After 5 minutes, stop the machine, reverse the hoses and repeat the flushing. Smart Junction Box Relay Box: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 7628 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 4622 5. CAUTION: Apply moderate air pressure in short bursts to prevent an uncontrolled release of the piston. NOTE: Inspect the brake caliper piston and bore for excessive wear, corrosion or pitting. If any of these conditions exist, a new caliper must be installed. Remove the caliper piston. 1. Place a block of wood between the brake caliper piston and the brake caliper housing. 2. Apply compressed air through the caliper jounce hose port to remove the piston. 6. Remove the dust boot. 7. CAUTION: Use a plastic or wooden pick to remove the piston seal from the caliper bore. A metal tool may scratch or nick the seal groove, which could result in a seal leak. Remove the piston seal from the brake caliper bore. 8. To assemble, reverse the disassembly procedure. ^ Lubricate the piston seal with clean brake fluid. Page 1285 Brake Light Switch: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 6013 ^ 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 6139 2. 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. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure. - 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. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCS ECU into the seat cushion pan bracket and install the rivets. - The OCS 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). 7. Position the foam pad to the seat cushion pan. 8. 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. Install seat cushion trim cover to seat cushion foam pad and attach the J-clips. 9. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 10. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). Page 696 P1635 - P1639: Testing and Inspection P1639 P1639 (Part 1) P1639 (Part 2) Description and Operation Four Wheel Drive Selector Switch: Description and Operation FOUR-WHEEL DRIVE (4WD) MODE SWITCH Typical 4WD Switch The 4WD control module provides the PCM with an indication of 4WD Low. This input is used to adjust the shift schedule. A 5.0-volt module pull-up indicates 4WD High or 2WD. Page 6039 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 1969 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. System Diagnosis P0340 - P0344: Testing and Inspection P0340 (Part 1) P0340 (Part 2) 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 Service and Repair Front Fender Liner: Service and Repair FENDER SPLASH SHIELD Exploded View Removal and Installation 1. Remove the 3 fender splash shield bolts. - To install, tighten to 8 Nm (71 lb-in). 2. Remove the 7 fender splash shield pin-type retainers. 3. Remove the 6 fender splash shield screws. 4. Remove the fender splash shield. 5. To install, reverse the removal procedure. Page 3314 Page 5959 Page 7538 Symbols Part 3 Page 5361 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 2726 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Front P0180 P0180 - P0184: Testing and Inspection P0180 P0180 (Part 1) P0180 (Part 2) Page 2516 Coolant Temperature Sensor/Switch (For Computer): Description and Operation ENGINE COOLANT TEMPERATURE (ECT) SENSOR Typical Engine Coolant Temperature (ECT) Sensor The ECT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance 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 ECT measures the temperature of the engine coolant. The sensor is threaded into an engine coolant passage. Page 1643 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 4141 Fluid - Differential: Fluid Type Specifications Differential Fluid Type Type ..................................................................................................................................................... ............. SAE 80W-90 Premium Rear Axle Lubricant Page 6985 Page 7982 Wiper Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 7490 Symbols Part 5 Page 7464 Special Tool(s) Page 3583 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 152 P0218 Page 3957 Torque Converter: Testing and Inspection Torque Converter Diagnosis Prior to installing a new or remanufactured torque converter, all diagnostic procedures must be followed. This is to prevent the unnecessary installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the decision be made to install a new or remanufactured torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. See: Transmission Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Initial Inspection/Preliminary Inspection 2. Know and Understand the Customers Concern. 3. Verify the Concern-Carry out the Torque Converter Operation Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Torque Converter Diagnosis 4. Carry out Diagnostic Procedures. ^ Carry out On-Board Diagnostics. See: Transmission Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes ^ Repair all non-transmission DTCs first. ^ Repair all transmission DTCs. ^ Rerun on-board diagnostics to verify repair. ^ Carry out Line Pressure Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Line Pressure Test ^ Carry out Stall Speed Test. See: Transmission Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Stall Speed Test ^ Carry out Diagnosis by Symptom Routines. Refer to Diagnosis By Symptom.See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines ^ Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose, and repair as required, before repairing the torque converter. Torque Converter Clutch Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating correctly. Carry out the test as follows: 1. Carry out On-Board Diagnostic Test. See: Transmission Control Systems/Testing and Inspection/Reading and Clearing Diagnostic Trouble Codes/Displaying & Reading Trouble Codes Refer to Computers and Control Systems. 2. Connect a tachometer to the engine. 3. Bring engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperatures are reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap the brake pedal with the left foot. 5. Engine rpm should increase when the brake pedal is tapped, and should decrease about 5 seconds after the brake pedal is released. If this does not occur, refer to Torque Converter Operation Concerns. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines/Torque Converter Concerns 240/340-242/342 If the vehicle is at a stop and stalls in (D) at idle, move the transaxle range selector lever to the manual 1 position. Refer to Torque Converter Operation Concerns. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines/Torque Converter Concerns 240/340-242/342 Refer to Diagnosis By Symptom. See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines Repair as required. If the vehicle does not stall in manual 1, refer to Diagnosis By Symptom.See: Transmission Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Diagnostic Routines Page 1632 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Brakes - Rear Disc Brake Grinding/Rubbing/Thumping Brake Rotor/Disc: All Technical Service Bulletins Brakes - Rear Disc Brake Grinding/Rubbing/Thumping TSB 05-13-8 07/11/05 REAR DISC BRAKE GRIND, RUBBING OR THUMP NOISE FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner This article supersedes TSB 05-9-25 to increase the labor operation time. ISSUE Some 2005 vehicles may exhibit a rear disc brake grind, rubbing or thump. The noise may be more noticeable during cool or wet conditions, and usually occurs during initial brake application after setting over night. This may be due to the composition of the brake lining material. ACTION Machine the rear rotors and install new rear disc brake linings made of revised material. Refer to Section 206-04 of the Workshop Manual. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051308A 2005 Escape, Manner, 1.5 Hrs. Escape Hybrid: Machine The Rear Brake Rotors And Install New Rear Disc Brake Linings (Do Not Use With 2001B, 2001B1, 2001B3P, 2001B3PT) DEALER CODING CONDITION BASIC PART NO. CODE 2200 D4 Disclaimer Page 6888 View 151-22 (Left Front Door) Page 3246 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Service and Repair Trunk / Liftgate Solenoid: Service and Repair LIFTGATE LATCH ACTUATOR Removal and Installation 1. Remove the liftgate latch remote control. 2. Remove the 2 liftgate latch actuator screws and the liftgate latch actuator. 3. To install, reverse the removal procedure. Battery Junction Box (BJB) Relay Box: Diagrams Battery Junction Box (BJB) Page 6294 E1-E3 Normal Operation The compass sensor module communicates the vehicle direction to the instrument cluster to display in the message center. Possible Causes - compass sensor module - vehicle is magnetized - zone setting - compass out of calibration Locations Page 1722 Difference From Standard Position (LH Side) 5. NOTE: Notice the position of the strut rod in each position. Use the following table for the RH side camber and or caster adjustment. Stub Shaft Pilot Bearing and Seal Seals and Gaskets: Service and Repair Stub Shaft Pilot Bearing and Seal Stub Shaft Pilot Bearing and Seal Special Tool(s) Material Removal Specifications Timing Chain Tensioner: Specifications Timing chain tensioner bolts ................................................................................................................ ................................................. 10 Nm (89 inch lbs.) Fuel Rail Pressure/Temperature Sensor Page 5957 Page 5289 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 7029 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 6596 Page 2613 Main Relay (Computer/Fuel System): Testing and Inspection Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 7331 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Suction Accumulator to Compressor Line Hose/Line HVAC: Service and Repair Suction Accumulator to Compressor Line SUCTION ACCUMULATOR TO COMPRESSOR LINE Page 4410 Page 7687 Symbols Part 4 Page 3450 Page 3021 Symptom Chart (Part 2) Service and Repair Trunk / Liftgate Lock: Service and Repair LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 4751 Torque Specifications Locations View 151-8 (Engine, rear) Page 5288 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Power Door Lock Switch, Passenger View 151-23 (Right Front Door) Page 3519 Front Impact Severity Sensor Impact Sensor: Service and Repair Front Impact Severity Sensor FRONT IMPACT SEVERITY SENSOR 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Locations View 151-7 (Engine, front) Page 1993 Pressure, Vacuum and Temperature Specifications Engine Oil Pressure: Pressure, Vacuum and Temperature Specifications Oil pressure (hot @ 2,000 rpm) ...................................................................................................................................................... 29-39 psi (200-268 kPa) Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 3875 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 175 P0264 Service and Repair Grille: Service and Repair RADIATOR GRILLE Removal and Installation 1. Remove the front bumper cover. 2. Remove the 2 radiator grille nuts. 3. Release the 15 clips and release the radiator grille. 4. To install, reverse the removal procedure. Page 7674 License Plate Lamp: Service and Repair LICENSE PLATE LAMP Removal and Installation 1. Push the license plate lamp housing to the right and pull it out. 2. Disconnect the electrical connector. 3. Remove the license plate lamp holder and lamp. 4. To install, reverse the removal procedure. Page 6014 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Forward Crash Sensor Page 5454 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 5164 Inspect the pulley for paint marks in the web area near the hub. If there are no paint marks, or one paint mark, use a paint pencil to mark the web area of the pulley near the hub. Using the special tool, install the power steering pump pulley. 2. Using the special tool, install a new seal on the power steering pressure hose fitting. ^ Remove and discard the original seal. ^ Stretch the seal over the seal replacer and slide it onto the tube nut. 3. Position the power steering pump and install the upper bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 4. Connect the power steering suction hose and clamp. 5. Position the power steering pressure line bracket and install the nut. ^ Tighten to 10 Nm (89 inch lbs.). 6. Raise the vehicle. 7. Install the lower power steering bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 8. Connect the power steering line fitting nut. ^ Tighten to 65 Nm (48 ft. lbs.). 9. Connect the power steering pressure switch electrical connector. 10. Install the drive belt. Refer to Drive Belts, Mounts, Brackets and Accessories. 11. Fill and leak check the power steering system. Locations Service and Repair Rear Door Window Regulator: Service and Repair REAR DOOR WINDOW REGULATOR Removal and Installation 1. Remove the rear door trim panel. 2. Remove the screw and the rear door trim panel bracket. 3. Position the watershield aside. 4. Connect the window control switch electrical connector. 5. Using the window control switch, lower the rear door window glass to gain access to the rear door window glass screws. 6. Disconnect the window control switch electrical connector. 7. Remove the 2 rear door window glass screws. - To install, tighten to 5 Nm (44 lb-in). 8. Support the rear door window glass in the full up position. 9. Disconnect the rear door window motor electrical connector. 10. Remove the 3 rear door window regulator and motor bolts. - To install, tighten to 6 Nm (53 lb-in). 11. Remove the 2 nuts and the rear door window regulator and motor. - To install, tighten to 6 Nm (53 lb-in). 12. To install, reverse the removal procedure. Page 4016 Inspect the O-ring seal for nicks or cuts. Install a new O-ring seal as necessary. 5. To install, reverse the removal procedure. Page 2853 1. Inspect the spark plugs. 2. Adjust the spark plug gap as necessary. 3. Install the spark plugs. - Tighten to 12 Nm (9 lb-ft). 4. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil boots before attaching to the spark plugs. Install the ignition coils and bolts. Tighten to 10 Nm (89 lb-in). 5. Connect the ignition coil electrical connectors. 6. Connect the battery ground cable. Page 2361 9. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. NOTE: This step will correctly align the crankshaft pulley to the crankshaft. Install a standard 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover. ^ Rotate the pulley as necessary to align the bolt holes. 10. CAUTION: Failure to hold the crankshaft pulley in place while tightening the bolt can cause damage to the engine front cover. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: ^ Stage 1: Tighten to 100 Nm (74 ft. lbs.). ^ Stage 2: Tighten an additional 90 degrees (1/4 turn). 11. Remove the 6-mm (0.23 inch) x 18-mm (0.7 inch) bolt. 12. Remove the special tool. Page 3926 7. CAUTION: Make sure that the plastic straw inside of the lever does not come out. Remove the knob and wiring by pulling straight up on the knob. 8. Carefully pry up the 4 bezel clips and remove the bezel. 9. Remove the gearshift bezel. Installation System Diagnosis P0420 Page 3641 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR F-150 Hall-Effect CMP Sensor Typical Variable Reluctance CMP Sensor The 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 PCM and used for synchronizing the sequential firing of the fuel injectors. Coil-on-plug (COP) ignition applications use the CMP signal to select the 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 2 CMP sensors are equipped with variable camshaft timing (VCT). They use the second sensor to identify the position of the camshaft on bank 2 as an input to the PCM. DTC P0345 is associated with this sensor and it is referred to as CMP2. There are 2 types of CMP sensors: the 3-pin connector Hall-effect type sensor (only used on F-150 4.2L applications) and the 2 pin connector variable reluctance type sensor used on all other vehicle applications. P0442 P0442 Page 4162 4. Line up the index marks and install the rear driveshaft universal joint. ^ Install the 2 cap straps and the 4 bolts. ^ Tighten to 23 Nm (17 ft. lbs.). Page 3019 I1-I4 I4 Continued Normal Operation The diagnostic tool is connected to the DLC C251 to communicate with both the high speed and medium speed controller area network (CAN), as Page 6278 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 concern is not visually evident, connect the diagnostic tool to the data link connector (DLC) 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: - CAN or ISO circuit fault; all electronic control units no response/not equipped, refer to Information Bus (Module Communications Network). - No response/not equipped for the instrument cluster, refer to Instrument Cluster. - System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs, and carry out self-test diagnostics for the instrument cluster. 7. If the DTCs retrieved are related to the concern, go to the Instrument Cluster Diagnostic Trouble Code (DTC) Index to continue diagnosis. For all other DTCs, refer to Body Control Systems (Multifunction Electronic Control Module). See: Diagnostic Trouble Code Descriptions 8. If no DTCs related to the concern are retrieved, GO to Symptom Chart to continue diagnosis. See: Symptom Related Diagnostic Procedures Page 1203 View 151-14 (Under Dash Panel, LH Side) Page 3415 Fuel Injector: Diagrams Page 6739 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer P2270 P2270 Connector Views Wiper Motor: Connector Views Page 4295 Transmission Mount: Service and Repair Rear Transaxle Rear Support Insulator Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the transaxle rear support insulator bolt. ^ To install, tighten to 90 Nm (66 ft. lbs.). 3. Remove the 2 transaxle rear support insulator nuts. ^ To install, tighten to 90 Nm (66 ft. lbs.). 4. Remove the transaxle rear support insulator through-bolt and washer. ^ To install, tighten to 90 Nm (66 ft. lbs.). 5. Remove the transaxle rear support insulator. 6. If necessary, remove the 3 bolts and the transaxle rear support insulator bracket. ^ To install, tighten to 90 Nm (66 ft. lbs.). 7. To install, reverse the removal procedure. Page 7666 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 5947 Air Bag Control Module: Description and Operation RESTRAINTS CONTROL MODULE (RCM) WARNING: - Do not handle, move or change the original horizontal mounting position of the restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow these instructions may result in the inadvertent deployment of the safety canopy and risk of personal injury. - The 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 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. 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 carries out the following functions: - deploys the air bag(s) in the event of a deployable crash. - activates the safety belt buckle pretensioners to remove slack from the safety belt. - monitors the 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. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the ON 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 prove out by lighting for 6 seconds and then off for 2 seconds. After the prove out, the air bag indicator will then flash the 2-digit LFC if a SRS fault exists. The air bag indicator will flash the LFC 5 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, to the diagnostic 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 5 sets of 5 tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If 2 or more faults occur at the same time, the fault having the highest priority will be displayed. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides 150 ms of backup power to deploy the front air bags and pretensioners in the event that the ignition circuit is lost or damaged during impact. The backup power supply will deplete its stored energy approximately 1 minute after the battery ground cable is disconnected. Page 728 P1780 - P1784: Testing and Inspection P1781 P1781 (Part 1) P1781 (Part 2) Page 7200 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 7035 119-2 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 1431 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Page 1185 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Rear Wheel Speed Sensor Ring-Rear Removal and Installation FWD vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel hub nut. ^ To install, tighten to 290 Nm (214 ft. lbs.). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. 4WD vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. Description and Operation Seat Belt Tension Sensor: Description and Operation SAFETY BELT TENSION SENSOR The safety belt tension sensor: - is part of the front outboard passenger safety belt and retractor assembly. - is located at the safety belt anchor point. - is used in conjunction with the occupant classification sensor (OCS) system. - is a 3-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, when the child safety seat is installed according to manufacturer instructions. 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. Rear Door Glass, Frames and Mechanisms - Exploded View Rear Door Window Glass: Service and Repair Rear Door Glass, Frames and Mechanisms Exploded View REAR DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. P0102 P0100 - P0104: Testing and Inspection P0102 P0102 (Part 1) P0102 (Part 2) Page 6145 7. Bend the retaining tab away from the pressure sensor, then slide the pressure sensor off the bracket. 8. CAUTION: Care must be taken to prevent damage to the seat cushion pan when removing the rivets. Remove the 2 rivets and detach OCS ECU from the seat cushion pan. 9. Remove the OCS. - Pull all the OCS components (hose, pressure sensor, wire harness, ECU and connectors) through the seat cushion pan opening. Installation 1. Bend the retaining tab back on the pressure sensor component bracket. Page 6929 Page 3285 4. NOTE: If installing a new converter, remove the heated oxygen sensor (HO2S) and the catalyst monitoring sensor for installation in the new converter. Disconnect the HO2S and the catalyst monitoring sensor electrical connectors. 5. Remove and discard the 7 exhaust manifold nuts. 6. Remove the catalytic converter from the vehicle. ^ Discard the exhaust manifold gasket. Installation 1. CAUTION: If the warpage is greater than 0.76 mm (0.03 inch) replace the catalytic converter. Inspect the catalytic converter for warpage across the manifold flange area. 2. Position a new exhaust manifold gasket on the engine. 3. CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak. CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak. NOTE: Make sure to tighten the nuts in the sequence in 2 stages. Position the catalytic converter and tighten the 7 exhaust manifold nuts in the sequence shown. ^ Stage 1: Tighten to 47 Nm (35 ft. lbs.). ^ Stage 2: Tighten to 47 Nm (35 ft. lbs.). 4. NOTE: Apply anti-seize lubricant to the threads of the sensors before installation. Page 7140 Brake Switch (Cruise Control): Service and Repair SPEED CONTROL DEACTIVATOR SWITCH Removal 1. Disconnect the electrical connector. 2. Rotate the speed control deactivator switch 45 degrees counterclockwise to disengage it from the bracket. Installation CAUTION: The initial installation of a speed control deactivator switch allows for adjustment. If additional adjustments are required, install a new switch. 1. Release the plunger lock. - Turn the lock knob counterclockwise until the first click is felt. 2. Press and hold the brake pedal. 3. Install the speed control deactivator switch. 1 Position the speed control deactivator switch in the bracket and rotate clockwise 45 degrees. Page 3646 Crankshaft Position Sensor: Diagrams Page 6762 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 1354 Page 5892 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Page 6867 Part 2 Removal and Installation 1. Disconnect the battery. 2. Open the 4 A-pillar passenger assist handle covers. 3. Remove the 4 bolts and the 2 A-pillar passenger assist handles. - To install, tighten to 5 Nm (44 lb-in). 4. Remove the 2 A-pillar trim panels. 5. Remove the 2 B-pillar trim panels. 6. Remove the 2 C-pillar trim panels. 7. Remove the 2 D-pillar trim panels. 8. Remove the 2 screws and the overhead console. - Disconnect the electrical connector. 9. Remove the 4 screws, the 2 sun visors and the 2 clips. - If equipped, disconnect the electrical connectors. 10. Remove the interior lamp lens. 11. Remove the 2 interior lamp screws and the front interior lamp. - Disconnect the electrical connector. 12. Remove the cargo lamp. - Disconnect the electrical connector. 13. Remove the 3 child seat tether anchor covers. 14. Remove the 3 bolts and the child seat tether anchors. - To install, tighten to 22 Nm (16 lb-ft). 15. If equipped, remove the 2 screws and the coat hooks. - To install, tighten to 7 Nm (62 lb-in). 16. Remove the 4 passenger assist handle bolts and the 2 passenger assist handles. - To install, tighten to 8 Nm (71 lb-in). 17. NOTE: When installing the retainer it should meet at the rear of the roof opening and have no gaps or overlaps. If equipped, remove the headliner retainer. 18. Remove the 5 headliner pin-type retainers. System Diagnosis P0243 Door Lock Switch, Passenger Side Power Door Lock Switch: Testing and Inspection Door Lock Switch, Passenger Side Page 2480 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 were good and did not require replacement. If a heater core leak is suspected, the heater core must be tested by carrying out the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose-to-heater core attachments. A coolant leak in the heater water 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-specification clamps can cause leakage at the heater water hose connection and damage the heater core. Check the integrity of the heater water hose clamps. Heater Core - Plugged WARNING: The heater core inlet hose will become too hot to handle if the system is working correctly. 1. Verify the engine coolant is at the correct level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches a normal operating temperature, feel the heater core inlet and outlet hoses to see if they are hot. If the inlet hose is not hot: the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. - the heater core may be restricted or plugged. Heater Core - Pressure Test Use the pressure tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. Clamp off the heater hoses. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install plug BT-7422-B and adapter BT-7422-A from the pressure tester in the heater water hose ends. Secure the heater water hoses, the plug, and the adapter with hose clamps. 5. Attach the pump and gauge assembly from the pressure tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of 3 minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform 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 water hoses with plug and adapter to the core tubes. Then connect the pressure tester to the adapter. Caliper Removal and Installation, Front Brake Caliper: Service and Repair Caliper Removal and Installation, Front Brake Caliper Material Material Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake caliper clip. 3. Loosen the brake caliper jounce hose at the brake caliper. ^ To install, tighten to 20 Nm (15 ft. lbs.). 4. Remove the 2 brake caliper dust boot caps. 5. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.) for disc-drum brake system. ^ To install, tighten to 45 Nm (33 ft. lbs.) for 4-wheel disc brake system. 6. Remove the brake caliper. ^ Unthread the brake caliper from the brake caliper jounce hose. 7. NOTE: Make sure that the brake caliper jounce hose is not twisted. To install, reverse the removal procedure. ^ Bleed the brake system. Connector Views Engine Control Module: Connector Views Page 7681 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 1224 Page 3497 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Service and Repair Thermostat Bypass Hose: Service and Repair Bypass Tube-2.3L Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the intake manifold. 4. Disconnect and remove the coolant bypass tube. 5. To install, reverse the removal procedure. 6. Fill and bleed the cooling system. Testing and Inspection Ignition Relay: Testing and Inspection Page 3293 Canister Purge Control Valve: Service and Repair EVAPORATIVE EMISSION CANISTER 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. Disconnect the battery ground cable. 2. Disconnect the evaporative emissions (EVAP) canister purge valve electrical connector. 3. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the Diagrams Page 5397 C. Apply Motorcraft Silicone Brake Caliper Grease and Dielectric Compound. (Figure 1) (1) To the entire length of the chrome strut rod above the jounce bumper and 360 degrees around the rod. (2) To the top and sides of the uppermost part of the dust boot. (3) Apply 360 degrees to the jounce bumper itself. d. Assemble front strut and install per WSM, Section 204-01. e. Repeat the procedure on the other side of the vehicle. 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 090605A 2001-2009 Escape, 0.7 Hr. 2005-2009 Escape Hybrid, Mariner 2006-2009 Mariner Hybrid: Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test (Do Not Use With 1007D, 18124A) 090605B 2001-2009 Escape, 1.5 Hrs. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Replace The Strut Dust Boots, Apply Grease Following Service Procedure. Includes Time To Evaluate Noise With Chassis Ears and Road Test Can Be Claimed With Operations C And D (Do Not Use With 1007D, 18124A) 090605C 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Check Caster, Camber and, Toe-In Can Be Claimed With Operation B And D (Do Not Use With 2001B, 2001B1, 2001B5, 2001B8, 2219D, 2219D2, 3185B, 3001A, 3001A6F) 090605D 2001-2009 Escape, 0.6 Hr. 2005-2009 Escape Hybrid, Mariner, 2006-2009 Mariner Hybrid: Correct Caster, Camber And Page 5842 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM is restored to its original condition. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. 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 air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Fuel Tank Pressure (FTP) Sensor Fuel Tank Pressure Sensor: Description and Operation Fuel Tank Pressure (FTP) Sensor FUEL TANK PRESSURE (FTP) SENSOR Fuel Tank Pressure (FTP) Sensor In-Line Fuel Tank Pressure (FTP) Sensor The FTP sensor or in-line FTP sensor is used to measure the fuel tank pressure during the EVAP leak check monitor. Page 6805 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 5590 Disclaimer Page 7774 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 8023 View 151-25 (Liftgate) Locations View 151-3 (Engine Compartment, 1 Of 2) Page 4863 Page 7248 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. See: Compass Zone Adjustment 3. Carry out the Compass Calibration Adjustment procedure. See: Compass Calibration Page 3202 Power Steering Pressure Switch: Diagrams Page 7811 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 4102 Shift Interlock: 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. 37-1 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: Page 7765 Page 4025 Valve Body: Service and Repair Main Control Valve Body Main Control Valve Body Special Tool(s) Material Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Disconnect the breather tube and Mass Air Flow (MAF) sensor. 4. Remove the intake tube and air cleaner cover. Page 6858 Starting on either side of the vehicle, position the supplied drill guide onto the foam block so that the locating pin is set into the indentation on top of the block and the "wings" are resting on either side of the block, preventing the guide from moving side-to-side. See Figure 4. 4. WARNING: WEAR SAFETY GLASSES. CAUTION: DO NOT USE an air-powered drill for this operation. Oil spray from the tool may damage the foam block or other interior trim. CAUTION: Be sure to keep the drill motor at full speed and frequently clear the chips from the bit while drilling each hole. Bore the holes at a slow to moderate pace using light to moderate pressure on the drill. Attempting to bore the holes at a fast pace using excessive pressure on the drill, or failing to clear the chips from the bit, may cause the foam blocks to crack. NOTE: Be sure to allow the drill motor to achieve full speed before attempting to bore the hole. Drill the holes as follows: A. Holding the drilling guide securely in place, position the drill bit in either of the two (2) guide holes. See Figure 5. B. Start the drill motor and allow it to achieve full speed. Page 4093 Shift Interlock: 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 6970 Sunroof / Moonroof: 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 7360 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 1259 Mechanical Returnless Fuel Pump Module (FPM) Page 7082 Power Door Lock Switch: Service and Repair DOOR LOCK CONTROL SWITCH Removal and Installation NOTE: LH side shown, RH side similar. 1. Remove the front door trim panel. 2. On Mariner vehicles, remove the 3 screws and the front door trim panel arm rest. 3. Release the bezel retaining clip from the door trim panel. 4. Release the locking clips and remove the window control switch. 5. To install, reverse the removal procedure. Page 3191 Page 76 P0132 Page 4639 3. Disconnect the electrical connector by rotating the protective cover. 4. Remove the brake line-to-HCU fittings. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. Remove the 3 HCU bracket-to-frame bolts. ^ To install, tighten to 23 Nm (17 ft. lbs.). 6. Remove the 3 ABS module screws. ^ To install, tighten to 2 Nm (18 inch lbs.). 7. Remove the ABS module. 8. Remove the 3 bracket-to-HCU bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 9. Remove the HCU. 10. To install, reverse the removal procedure. ^ Bleed the brake system. Page 7447 Brake Lamp: Connector Views Page 2587 Page 875 Page 6071 3. Cut and strip the wires near the electrical connector. 4. Obtain 2 wires (20 gauge minimum) at least 6.1-meters (20-feet) long and attach 1 end of each wire to stripped ends of the pretensioner wires. Safety belt retractor pretensioner 5. Cut off 125 mm (4.92 in) of the vehicle body harness with the connector and strip 25 mm (1 inch) of insulation off the wires. 6. Obtain 2 wires (20 gauge minimum) at least 6.1-meters (20-feet) long and attach 1 end of each wire to stripped ends of the pretensioner wires. All pretensioners 7. Position the safety belt retractor/buckle pretensioner assembly on a flat surface in an open outdoor area so that moveable parts do not contact the support surface. 8. Remain at least 6.1-meters (20-feet) away from the safety belt pretensioner. Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ............................. 1.25 - 1.35mm (0.049 - 0.053 in.) Spark Plug Tightening Torque ............................................................................................................. ........................................................ 12 Nm (9 lb.ft.) Component Locations Page 5283 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Locations View 151-7 (Engine, front) Page 7221 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 2711 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the catalyst monitor sensor electrical connector. Right/Left Front View 151-3 (Engine Compartment, 1 Of 2) Page 5984 2. Remove the bolt and the child safety seat tether anchor. - To install, tighten to 22 Nm (16 lb-ft). 3. WARNING: It is important that the bolt/anchor be securely tightened to specification. Otherwise, the child's safety seat may not be properly secured, and the child can be injured in case of a sudden stop or accident. NOTE: Rework the sheet metal to its original condition and structural integrity. - Make sure to tighten the bolts to specification. To install, reverse the removal procedure. Page 882 Page 133 P0192 Page 1673 Power Window Switch: Testing and Inspection Window Adjust Switch Page 4294 2. Using the special tool, support the engine. 3. Remove the front-to-aft crossmember. 1 Remove the 2 transaxle front support insulator bolts. ^ To install, tighten to 90 Nm (66 ft. lbs.). 2 Remove the splash shield screw. 3 Remove the 2 front-to-aft crossmember bolts and nut. ^ To install, tighten to 90 Nm (66 ft. lbs.). 4 Remove the crossmember. 4. Remove the through-bolt and the transaxle front support insulator. ^ To install, tighten to 90 Nm (66 ft. lbs.). 5. If necessary, remove the 3 bolts and the transaxle front support insulator bracket. ^ To install, tighten to 55 Nm (41 ft. lbs.). 6. To install, reverse the removal procedure. Page 1469 View 151-8 (Engine, rear) Page 4191 1. Lubricate the outer CV joint with grease. 2. Install the outer CV boot on the front drive halfshaft. 3. Install a new front drive halfshaft bearing retainer circlip. 4. Using a soft-face hammer, install the outer CV joint by gently tapping it onto the front drive halfshaft. 5. Remove any excess grease on the mating surfaces and slide the outer front drive halfshaft joint boot onto the outer CV joint. 6. Adjust the outer CV boot spacing and remove any excess air trapped in the outer front drive halfshaft boot using a cloth-covered screwdriver. 7. Using the special tool, install the 2 new outer CV boot clamps. 8. Position the inner CV boot on the front drive halfshaft. Service and Repair Band Apply Servo: Service and Repair Overdrive Servo Special Tool(s) Removal 1. NOTE: Servicing the intermediate/overdrive servo in the vehicle is only recommended in the event of a leak. If the servo has failed it will be necessary to remove and disassemble the transaxle to inspect the intermediate/overdrive band assembly and direct clutch for damage. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. 3. Remove the transmission fluid cooler line bracket and bolt and position it aside. 4. WARNING: The servo is under pressure. Servo and servo cover are under high spring force. Use caution when removing servo cover. Failure to follow these instructions may result in personal injury. Page 3862 2. Using the special tool, align the TR sensor and tighten the bolts. ^ Tighten to 12 Nm (9 ft. lbs.). 3. Connect the TR sensor electrical connector. 4. Install the battery and tray. 5. Check the correct operation. The engine should start only in PARK or NEUTRAL. The reverse lamps should illuminate in the REVERSE position. Page 1690 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 1563 REFER TO SECTION 501-20B OF THE WORKSHOP MANUAL FOR COMPLETE DETAILS OF SYSTEM OPERATION. PAD LAMP OPERATION: Intermittent illumination of the PAD lamp typically occurs with passengers weighing approximately 100 pounds (45 KG). If the passenger shifts their weight, the occupant classification system (OCS) may determine that the seat is occupied by a child. The PAD lamp (located in the center bezel beneath the radio) is not a system malfunction indicator, and will not generate DTCs. It is only a system status light and illuminates to indicate that the passenger air bag is deactivated. DTC C1414: Illumination of the supplemental restraint system (SRS) indicator lamp in the instrument cluster, with DTC C1414 (Incorrect Vehicle ID), will only occur if an incompatible OCS service part is installed during a repair. There are three different levels of production and service parts used in the 2005 model year, based on the build date of the vehicle. The components of the three systems are not interchangeable. Code C1414 indicates that an OCS component or the RCM are not matched to each other or to the vehicle's build date. To resolve, ensure correct components are installed. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 051514A 2005 Escape, Escape 1.3 Hrs. Hybrid, Mariner Install OCS Kit (Do Not Use With 14056D 63222A) DEALER CODING CONDITION BASIC PART NO. CODE 78632A22 42 Disclaimer Electronic Throttle Body (ETB) Position Sensor Throttle Position Sensor: Description and Operation Electronic Throttle Body (ETB) Position Sensor ELECTRONIC THROTTLE BODY (ETB) POSITION SENSOR For information on the electronic throttle body position sensor, refer to the description of the ETB in Torque Based Electronic Throttle Control (ETC). Page 7392 P0720 P0720 P2121 P2121 Page 5572 Removal 1. Remove the A/C compressor. 2. Using the special tool, remove the A/C clutch bolt. 3. Remove the A/C disc and hub assembly and the A/C clutch hub spacers. 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 clutch disc and hub assembly and the A/C clutch disc and hub spacers from the compressor shaft. Page 6267 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 4619 Brake Caliper: Service and Repair Caliper Removal and Installation, Rear Brake Caliper Material Material Removal and Installation 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. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Install new copper washers. Remove the brake caliper jounce hose flow bolt and discard the 2 copper washers. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 4. Remove the brake caliper. 5. To install, reverse the removal procedure. ^ Bleed the brake system. Page 3595 Page 6764 Rear Subframe: Service and Repair REAR SUBFRAME Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. Vehicles with 4WD 2. Remove the rear axle assembly. All vehicles Page 7229 Symbols Part 4 Page 647 P1507 Page 140 P0198 Page 3286 If installing a new converter, install the HO2S and the catalyst monitoring sensor using the special tool. ^ Tighten to 47 Nm (35 ft. lbs.). 5. Connect the H02S and the catalyst monitoring sensor electrical connectors. 6. Position the heat shield and install the 6 heat shield bolts. ^ Tighten to 10 Nm (89 inch lbs.). 7. Install the 2 catalytic converter bracket bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 8. Install the exhaust flexible pipe. Page 5924 Side Air Bag: Service and Repair SIDE AIR BAG MODULE 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. - Side air bag modules with damaged covers must be replaced. - Front seat back trim covers installed on seats equipped with side air bags cannot be repaired, they are to be replaced. Cleaning is permissible. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ............................................................................................................................................ ........................................................... 4.25L (4.5 Qt) Page 1664 View 151-22 (Left Front Door) P0020 P0020 Page 7498 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 4594 Brake Drum: Description and Operation Drum Brake The rear drum brake uses a pedal actuated rear wheel cylinder to move the rear brake shoes against the brake drum. After the initial setting, the rear drum brake adjustment is maintained through periodic parking brake operation. For initial setting, refer to Brake Shoe Adjustment. The drum brake system consists of the following components: ^ bleeder screw dust cap ^ bleeder screw ^ brake adjusting hole cover ^ brake backing plate ^ brake drum ^ brake shoes ^ brake shoe hold-down clip ^ brake shoe hold-down clip pin ^ brake shoe retracting spring ^ parking brake cable ^ parking brake lever ^ parking brake lever pin ^ parking brake return spring ^ self-adjuster ^ self-adjuster lever ^ self-adjuster spring ^ wheel cylinder ^ wheel cylinder bolts ^ wheel cylinder piston dust boot ^ wheel cylinder piston ^ wheel cylinder piston seal Page 1399 View 151-8 (Engine, rear) Page 3884 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 7783 Symbols Part 5 Page 801 P2123 Page 7682 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 7981 Page 5290 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 control arms. - provide a mounting point for the engine isolators. - provide the mounting surface for the steering gear. - provide the mounting surface for the sway bar. Page 6316 E1-E4 Normal Operation The audio unit receives signals from the global positioning system (GPS) satellites through the GPS antenna and computes the vehicle position. The vehicle position is then displayed based on the map CD. Possible Causes - circuit 140 (BK/PK) open or short to ground - map CD version - anti-lock brake system (ABS) module - audio unit Test F: The Navigation System Does Not Operate Correctly - The Fuel Economy & Energy Flow Screens Do Not Display Real Time Data PINPOINT TEST F: THE NAVIGATION SYSTEM DOES NOT OPERATE CORRECTLY - THE FUEL ECONOMY AND ENERGY FLOW SCREENS DO NOT DISPLAY REAL TIME DATA Page 7298 A1-A2 Normal Operation The message center display is located in the center of the instrument cluster. The messages are dependant on various vehicle inputs. Possible Causes - instrument cluster - message center switch(es) Test B: The Turn Signal On Warning Display Is Inoperative PINPOINT TEST B: THE TURN SIGNAL ON WARNING DISPLAY IS INOPERATIVE B1-B3 Normal Operation The turn signal on reminder warning feature alerts the operator that one of the turn signals has been on for 1/2 mile or more. Possible Causes - turn signals - circuitry - instrument cluster Test C: The Message Center Switch Does Not Operate Correctly Page 4227 Escape/Mariner and is not interchangeable. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the ground strap bolt. ^ To install, tighten to 40 Nm (30 ft. lbs.). 3. CAUTION: Do not reuse the CV joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur. Remove and discard the 6 front driveshaft-to-transfer case bolts and washers. ^ To install, tighten to 37 Nm (27 ft. lbs.). 4. Index-mark the front driveshaft to the center bearing. 5. CAUTION: Do not reuse the bolts and cap straps for the center U-joint. Install new bolts and cap straps or damage to the vehicle may occur. NOTE: There is a difference in the length of the head of the replacement cap strap bolts from the production bolts. The longer head pinion bolts can be used in either location. Remove and discard the 4 universal joint cap strap bolts and 2 cap straps and remove the front driveshaft. ^ To install, tighten to 23 Nm (17 ft. lbs.). 6. Index-mark the pinion and yoke to the driveshaft. 7. CAUTION: Do not reuse the bolts and cap straps for the rear U-joint. Install new bolts and cap straps. NOTE: There is a difference in the length of the head of the replacement strap bolts from the production bolts. The longer head pinion bolts can be used in either location. Remove and discard the 4 universal joint cap bolts and 2 cap straps from the rear driveshaft universal joint. ^ To install, tighten to 23 Nm (17 ft. lbs.). 8. With the help of an assistant, remove the center bearing support nuts and the driveshaft. ^ To install, tighten to 48 Nm (35 ft. lbs.). 9. NOTE: If a driveshaft is installed and driveshaft vibration is encountered after installation, index the driveshaft. To install, reverse the removal procedure. Page 3162 Fuel Tank Pressure Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Diagrams Page 516 P1235 - P1239: Testing and Inspection P1237 P1237 (Part 1) P1237 (Part 2) Page 2147 1. NOTE: Camshaft journals must be within specifications before checking runout. Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout. ^ Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. ^ If out of specification, install new components as necessary. Page 3089 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: Specifications Valve Clearance: Specifications NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. If any tappets do not measure within specifications, install new tappets in these locations. Page 5796 10. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger side safety canopy module electrical connector. 11. Connect the passenger side safety canopy module electrical connector. 1 Connect the passenger side safety canopy module electrical connector. 2 Slide and engage the passenger side safety canopy module electrical connector locking clip. 12. Install the passenger side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Escape and Mariner vehicles 13. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. Page 7693 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 6848 C. Drill the hole at a slow to moderate pace, occasionally pulling the bit out to clear the chips. D. Drill the hole to the proper depth using the stop on the bit as your depth gauge. See Figure 6. E. Drill the second hole in the same foam block in the same manner. F. Repeat steps A - E on the foam block on the other side of the headliner. 5. Remove the covers from the instrument panel and clean all foam chips from the vehicle. Proceed to ASSEMBLY. ASSEMBLY 1. Position the B-pillar trim panels and install the bolts. Tighten to 7 Nm (62 lb-in), then install the bolt covers. 2. Position the safety belt and install the safety belt bolts at the B-pillar. Tighten to 53 Nm (39 lb-ft), then install the D-ring covers. 3. Install the A-pillar trim panels. 4. Install the passenger A-pillar assist handles and bolts. Tighten to 5 Nm (44 lb-in), then install the bolt covers. 5. Install the front and rear door weatherstrips. 6. Connect and install the overhead console, if equipped. 7. Install and connect the interior lamp and screws. 8. Install the interior lamp lens. 9. Install the sunvisors, connecting the electrical connectors if equipped, and the sunvisor clips. 10. Install the rear seat overhead assist handles and bolts. Tighten to 8 Nm (71 lb-in), then install the bolt covers. Owner Letter Owner Notification Letter will be mailed on May 19, 2006. Page 5444 low spot of wheel run out. If the wheel assembly is now acceptable, continue with rebalance. If not, replace the tire with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. 5. Install the lowest R1H level tires on the front of the vehicle. 6. Install the lug nuts and torque to 98 lb-ft (133 N-m). WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052006A 2005-2006 Escape/Mariner 0.8 Hr Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, If Concern Is Solved, Return To Customer 052006B 2005-2006 Escape/Mariner 1.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires 052006C 2005-2006 Escape/Mariner 1.8 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 052006D 2005-2006 Escape/Mariner 2.2 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 1 Tire 052006E 2005-2006 Escape/Mariner 2.6 Hrs Built Before July 1, 2005: 20 Mile (33Km) Vibration Evaluation, Balance 4 Tires, Re-index 4 Tires, Re-balance 4 Tires, Replace 4 Tires (Do not use with operation 1007D, 1007AT, 1007AF, 1007AFT, 1OO7AB, 1007ABT, 1007D2A, 1007D2B, 1007AD2C, 1007AD2T, 1007D3T, 1007D3F, 1007D3FT, 1007D3B, 1007D3BT) DEALER CODING CONDITION BASIC PART NO. CODE (OPERATION A) NPF 82 (NPF) (OPERATION B, C) ALBAL D9 (ALBAL) (OPERATION D, E) TIRE 13 (TIRE) Page 6289 PINPOINT TEST C: THE MESSAGE CENTER SWITCH DOES NOT OPERATE CORRECTLY C1-C2 Description and Operation Transmission Mode Switch: Description and Operation TRANSMISSION CONTROL SWITCH (TCS) Typical Transmission Control Switch (TCS) Typical Transmission Control Switch (TCS) The TCS signals the PCM with VPWR whenever the TCS is pressed. On vehicles with this feature, the transmission control indicator lamp (TCIL) illuminates when the TCS is cycled to disengage overdrive. The operator of the vehicle controls. the position of the TCS. Transmission Control Indicator Lamp (TCIL) The TCIL is an output signal from the PCM that controls the lamp on/off function depending on the engagement or disengagement of overdrive. Refer to the PCM Inputs Transmission Control Switch in this section. Page 6986 Power Seat Motor: Service and Repair FRONT SEAT TRACK MOTOR Removal WARNING: - Always wear safety glasses when repairing a 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 reduce the risk of personal injury, do not use any memory saver devices. - The tightening torque of the seat track fasteners is critical for proper seat track system operation. Failure to follow these instructions may result in the failure of the seat to perform as designed with resultant risk of personal injury to the vehicle occupant. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Wear protective gloves as needed when handling components or parts that have pointed or sharp edges. 1. Move the seat so the front and rear vertical motors are positioned in the middle of their travel. 2. NOTE: If the seat does not move while activating the seat control switch, push on the seat cushion in the direction needed while activating the switch. If the seat cannot be moved, a new seat track assembly must be installed. Remove the seat and depower the SRS. 3. Remove the seat track. 4. Disconnect the seat track motor electrical connector. To change the seat track horizontal position, apply power and ground to the pins shown. 5. Mark the position of the electrical connector bracket, remove the two bolts and then remove the bracket. Page 6781 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 6446 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 1009 Brake Master Cylinder-Bypass Condition Test Brake Master Cylinder: Testing and Inspection Brake Master Cylinder-Bypass Condition Test Brake Master Cylinder-Bypass Condition Test 1. Check the brake hydraulic system for leaks or insufficient brake fluid. Repair as necessary. 2. Observe the brake fluid level in the brake master cylinder reservoir while the brake pedal is slowly applied and released. If the brake fluid level rises when the brake pedal is applied and drops when the brake pedal is released, but the net brake fluid level remains unchanged, the brake master cylinder is bypassing. Repair or install a new brake master cylinder. Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUGS Exploded View Removal 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connectors. 3. Remove the bolts and the ignition coils. 4. NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. Remove the spark plugs. Installation Page 6474 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 6082 Seat Sensor/Switch: Description and Operation SEAT TRACK POSITION SENSOR The seat track position sensor is a Hall-effect sensor located on the driver seat track. The seat track position sensor informs the restraints control module (RCM) of the driver seat position. Based on programmed limits, the seat track position sensor will inform the RCM of the driver seat position. The RCM uses this information in determining the deployment rate of the dual-stage driver air bag module. Page 481 P1132 Page 7781 Symbols Part 3 Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Deactivator Switch View 151-14 (Under Dash Panel, LH Side) Output Shaft Speed (OSS) Sensor Vehicle Speed Sensor: Description and Operation Output Shaft Speed (OSS) Sensor OUTPUT SHAFT SPEED (OSS) SENSOR The OSS sensor provides the PCM with information about the rotational speed of an output shaft. The PCM uses the information to control and diagnose powertrain behavior. In some applications, the sensor is also used as the source of vehicle speed. The sensor may be physically located in different places on the vehicle, depending upon the specific application. The design of each speed sensor is unique and depends on which powertrain control feature uses the information generated. Seat Belt Buckle Sensor Seat Sensor/Switch: Diagrams Seat Belt Buckle Sensor Page 5992 Seat Belt: Service and Repair Safety Belt With Anchor Plate Thread Damage SAFETY BELT WITH ANCHOR PLATE THREAD DAMAGE 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchor plate with a 10.7 mm (27/64 in.) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with the repair parts indicated in the Safety Belt Parts Replacement Guidelines. 6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from the underside of the floorpan. System Diagnosis P1549 Page 4195 Removal CAUTION: Never pick up or hold the halfshaft by only the inner or outer Constant Velocity (CV) joint. CAUTION: Handle the halfshaft by only the interconnecting shaft to avoid pull-apart and potential damage to the CV joints. CAUTION: Do not over-angle the CV joints. CAUTION: Damage will occur to an assembled inner CV joint if it is over-plunged outward from the joint housing. CAUTION: Never use a hammer to remove or install the halfshafts. CAUTION: Never use the halfshaft assembly as a lever to position other components. Always support the free-ends of the halfshaft. CAUTION: Do not allow the boots to contact sharp edges or hot exhaust components. CAUTION: Do not drop assembled halfshafts. The impact may cut the boots from the inside without evidence of external damage. 1. NOTE: The LH side is shown, the RH side is similar. Remove the rear coil spring. 2. Remove and discard the rear wheel hub nut. 3. CAUTION: Support the wheel knuckle. Remove the nut and separate the lower ball joint. Page 4902 Page 1145 Recall - Interior Impact Non-Compliance Technical Service Bulletin # 06C12 Date: 060512 Attachment I - Administrative Information Page 4719 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Ring-Rear Wheel Speed Sensor Ring-Rear Removal and Installation FWD vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the wheel hub nut. ^ To install, tighten to 290 Nm (214 ft. lbs.). 3. Remove the sensor ring from the wheel hub. 4. To install, reverse the removal procedure. 4WD vehicles 5. The rear wheel speed sensor ring is integral to the rear axle halfshaft and cannot be repaired separately. Page 6451 Page 4008 View 151-10 (Automatic Transmission) Locations View 151-7 (Engine, front) Page 3044 Manifold Pressure/Vacuum Sensor: Diagrams Page 4209 Special Tool(s) Removal NOTE: If removing the wheel hub, the wheel bearing must be replaced. 1. Remove the wheel knuckle. 2. Using the special tool, press the wheel hub from the wheel bearing. P1385 P1385 Page 4087 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 954 7. Remove the SJB screw. 8. Disconnect the electrical connectors and remove the SJB. 9. To install, reverse the removal procedure. - Configure the SJB. Refer to Information Bus (Module Communications Network). Specifications Crankshaft Main Bearing: Specifications Crankshaft Main bearing journal diameter ................................................................................................................................. 51.980-52.000 min (2.046-2.047 in.) Main bearing clearance ............................................................................................................................................ 0.019-0.035 mm (0.0007-0.0013 in.) Main bearing bore diameter ..................................................................................................................................... 57.020-57.038 min (2.244-2.245 in.) Master Window/Door Lock/Unlock Switch Page 7367 P0112 P0112 Page 7939 Front Door Window Glass: Service and Repair Glass, Frames and Mechanisms - Exploded View FRONT DOOR GLASS, FRAMES AND MECHANISMS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Smart Junction Box Fuse Block: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 4678 Vacuum Brake Booster: Testing and Inspection Brake Booster-Operation Check 1. Inspect all vacuum hoses and connections. All unused vacuum connections must be capped. Hoses and their connections must be correctly secured and in good condition with no holes, cracks, or collapsed areas. 2. Check the brake hydraulic system for leaks or insufficient brake fluid. Repair as necessary. 3. With the engine off, place the transaxle in PARK (A/T) or NEUTRAL (M/T) and apply the parking brake. 4. NOTE: If the power brake booster is noisy when the brakes are applied, a new component must be installed. Apply and hold the brake pedal several times to exhaust all of the vacuum reserve from the system. 5. Apply and hold the brake pedal. 6. Start the engine. If the vacuum system is operating, the brake pedal will move downward slightly under constant foot pressure. If no movement occurs, the power brake booster system is not functioning. Turn the engine off. 7. Remove the vacuum hose from the power brake booster. 8. Place the transaxle in PARK (A/T) or NEUTRAL (M/T) and apply the parking brake. Start the engine. Manifold vacuum should be available from the vacuum booster hose. If manifold vacuum is not available, inspect all of the hoses and hose connections. Repair as necessary. 9. Connect the vacuum booster hose and run the engine at fast idle for 10 seconds. 10. Turn off the engine and let the vehicle stand for 10 minutes. 11. Apply the brake pedal with approximately 89 Newtons (20 lbs) of force. The brake pedal feel should be the same as normal power-assisted brake operation for at least one brake pedal application. If the brake pedal feel is normal, the power brake booster is OK. If the brake pedal feels hard, continue with the test. 12. Remove the vacuum booster hose from the power brake booster. Apply 57.3 kPa (17 in-Hg) of vacuum to the vacuum booster hose. If the vacuum does not leak off after 10 minutes, install a new power brake booster. If the vacuum does leak off, install a new check valve and/or new vacuum booster hoses. Page 3302 2. Disconnect the battery ground cable. 3. Disconnect the evaporative emission (EVAP) canister vent solenoid electrical connector. 4. Disconnect the fuel vapor hose from the dust separator. 5. Squeeze the coupling opposite of the release tabs and pull to release the fuel vapor tube quick connect coupling from the EVAP canister. 6. Remove the 2 nuts, 3 bolts and the EVAP canister assembly. - To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. 8. Carry out the evaporative emission system leak test. See: Testing and Inspection/Evaporative Emission System Leak Test 9. Carry out the evaporative emission repair verification drive cycle. See: Testing and Inspection/Evaporative Emission Repair Verification Drive Cycle Page 1031 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 5926 6. Pull and remove the manual lumbar knob. All seats 7. Fully recline the seat backrest. 8. Release the seat back trim cover J-clip. 9. Move the seat backrest to the upright position. 10. 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). 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. Place a hand between the seat backrest trim cover and foam pad and carefully separate the hook and loop strips. 11. Carefully roll up the seat back trim cover in an inside out fashion to the side air bag module. 12. Release the hook and loop retainer from around seat backrest frame. Page 7812 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 3412 System Diagnosis P005x Page 2590 Engine Control Module: Service and Repair Removal and Installation POWERTRAIN CONTROL MODULE (PCM) Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the powertrain control module (PCM) stud bolt nut and position the wiring harness aside. - To install, tighten to 9 Nm (80 lb-in). 3. Disconnect the 3 PCM electrical connectors. 4. Remove the stud bolts and the PCM. - To install, tighten to 9 Nm (80 lb-in). 5. Remove the PCM cowl seal. 6. To install, reverse the removal procedure. Page 5235 WARRANTY STATUS: Information Only Disclaimer Page 5182 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Parking Brake Cable-Front Parking Brake Cable: Service and Repair Parking Brake Cable-Front Parking Brake Cable-Front Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the parking brake control. 3. Disconnect the front parking brake cable from the equalizer bracket by compressing the cable conduit locking tabs. 4. Release the front parking brake cable pass-through grommet from the vehicle underbody. 5. Remove the front parking brake cable by pulling the front parking brake cable through the equalizer bracket. 6. To install, reverse the removal procedure. Locations View 151-4 (Engine Compartment, 2 Of 2) Page 2705 Page 358 P0602 Service and Repair Steering Column Lock: Service and Repair STEERING COLUMN LOCK MODULE Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the ignition switch. 2. NOTE: Clean all metal shavings and debris after cutting slots in the steering lock module bolts. Cut slots into the heads of the 2 steering lock module bolts. 3. Remove the 2 steering lock module bolts. ^ Discard the steering lock module bolts. 4. Remove the steering lock module clamp. 5. Remove the steering lock module. 6. To install, reverse the removal procedure. ^ Align the ribs on the steering lock module with the window of the steering column tube. ^ Align the locating pin with the slot on the locating bracket of the steering column. ^ Tighten the steering lock module bolts until the heads of the bolts shear off. Page 7790 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 8037 Wiper Switch: Testing and Inspection Page 3002 A1-A2 Normal Operation The PCM communicates with the diagnostic tool through the high speed CAN communications network, circuits 1908 (WH) and 1909 (BK). If one of the bus wires becomes shorted to ground or voltage, communications can continue at a reduced level. The PCM and instrument cluster share network termination responsibilities with the use of a split termination resistor in each module. If either of these termination resistors is lost, network communication is not possible. Check circuits 1908 (WH) and 1909 (BK) between the PCM C175b and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in one of the high speed CAN circuits, damage to the DLC C251, damage to the PCM C175b, or a problem in an in-line connector. Possible Causes - high speed CAN circuits 1908 (WH) and 1909 (BK) open - DLC C251 - PCM C175b - PCM - instrument cluster - PCM or instrument cluster termination resistors Test B: The Restraint Control Module (RCM) Does Not Respond to The Diagnostic Tool PINPOINT TEST B: THE RESTRAINT CONTROL MODULE (RCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Page 553 P1276 Page 3523 Fuel Temperature Sensor: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 6808 6. Connect the passenger seat side air bag module electrical connector and then slide and engage the seat side air bag electrical connector locking clip. Vehicles with safety canopies 7. Remove the restraint system diagnostic tool from the vehicle harness side of the driver side safety canopy module electrical connector. 8. Connect the driver side safety canopy module electrical connector. 1 Connect the driver side safety canopy module electrical connector. 2 Slide and engage the driver side safety canopy module electrical connector locking clip. 9. Install the driver side D-pillar trim panel. 1 Engage the D-pillar trim panel to the quarter trim panel. 2 Install the D-pillar trim panel. 3 Install the weatherstrip. Page 5014 Page 7399 Electronic Returnless Fuel Pump Module (FPM) The fuel pump (FP) module is a device that contains the fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump continuously refills the reservoir with fuel, and a check valve located in the manifold outlet maintains system pressure when the fuel pump is not energized. A flapper valve located in the bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial fill. Locations View 151-7 (Engine, front) Page 7533 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 3682 Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Capacity Refill ..................................................................................................................................................... .......................................................... 2.95 pts. (1.4L) Page 1957 Brake Bleeding: Service and Repair Manual Bleed Manual Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: When any part of the hydraulic system has been disconnected or a new component is installed, air may enter the system, causing spongy brake pedal action. This requires the bleeding of the hydraulic system after it has been correctly connected. 1. CAUTION: Be sure to check the brake fluid level in the brake master cylinder reservoir often. Do not let it run dry. Fill the brake master cylinder reservoir with the specified brake fluid. 2. Begin bleeding the system, going in order from the RH rear wheel, to the LH rear wheel, to the RH front wheel, and ending with the LH front wheel. 3. Attach a rubber drain hose to the rear bleeder screw and submerge the free end in a container partially filled with clean brake fluid. 4. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the brake pedal. 5. Loosen the bleeder screw until the fluid flow stops. Maintain pressure on the brake pedal and tighten the bleeder screw. 6. Repeat Steps 4 and 5 until clear, bubble-free brake fluid flows. 7. Tighten the bleeder screw to 16 Nm (12 ft. lbs.). ^ Refill the brake master cylinder reservoir as necessary. 8. Continue bleeding the brake hydraulic system at each wheel. 9. Fill the brake master cylinder reservoir with the specified brake fluid. Page 6137 and ECU) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electronic control unit (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 the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connectors and wiring clips. 1 Disconnect the OCS ECU electrical connector. 2 Disconnect the pressure sensor electrical connector. 3 Release the 2 wiring clips on the wiring harness from the cushion pan. 4 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. Locations Locations View 151-3 (Engine Compartment, 1 Of 2) Page 1349 Crankshaft Position Sensor: Service and Repair CRANKSHAFT POSITION (CKP) SENSOR Timing Peg, Crankshaft Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. Page 1640 Page 3477 1. Position the fuel tank filler pipe assembly in the vehicle. - Install the fuel filler pipe hose and clamp onto the fuel tank. - Tighten to 4 Nm (36 lb-in). 2. Connect the fuel vapor vent hose to the evaporative emissions canister. 3. Attach the fuel vapor vent hose retainer clips. 4. CAUTION: Make sure the vapor 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 the tube into the connector. Connect the fuel vapor control tube assembly valve quick connect coupling onto the fuel tank filler tube. Pull on the coupling to make sure it is fully engaged. 5. Install the fuel filler pipe mounting screw. - Tighten to 10 Nm (89 lb-in). 6. Using the special tool, install the fuel tank tube shield with new rivets. 7. Install the 2 fuel filler pipe mounting screws. - Tighten to 5 Nm (42 lb-in). 8. Turn the ignition key to the ON position to pressurize the fuel system. 9. Visually inspect the fuel system for leaks. Page 7775 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 6554 Front Door Exterior Handle: Service and Repair Front Door Handles, Locks and Latches Exploded View FRONT DOOR HANDLES, LOCKS AND LATCHES - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 406 P0721 Service and Repair Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt. 4. Remove the 2 bolts and the accessory drive belt tensioner. ^ To install, tighten to 25 Nm (18 ft. lbs.). 5. To install, reverse the removal procedure. Liftgate Ajar Switch Page 4364 ^ If the vent is too high, repeat Step 3. 5. CAUTION: Make sure the transfer case vent boot is correctly aligned. NOTE: Use a soapy water solution to lubricate the transfer case breather boot. Install the transfer case vent boot. 6. Install the transfer case. Page 7096 Page 3417 Page 2309 Flexplate, Flywheel and Crankshaft Rear Oil Seal Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Page 1307 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Description and Operation Intake Air Temperature Sensor: Description and Operation INTAKE AIR TEMPERATURE (IAT) SENSOR Typical Stand 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 IAT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases, and the resistance increases as the temperature decreases. The varying resistance affects the voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding to temperature. 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. Initial Inspection and Diagnostic Overview Navigation System: 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 the symptom and GO to Symptom Chart. See: Symptom Related Diagnostic Procedures Upgrading The Audio/Navigation Unit Software To carry out an audio/navigation unit software upgrade, the following steps must be taken: 1. CAUTION: Do not remove power from the audio unit during the software update. Turn the ignition switch to the ON or ACC position. 2. Turn the audio/navigation unit ON. 3. Install a new navigation database CD. 4. If the audio unit recognizes a revised level of software, it prompts the user to confirm whether they would like to carry out a software upgrade. When the Updating System Software screen is displayed, press the YES button on the display screen to accept the software update. 5. The audio unit carries out a unit reset, upgrades the software and carries out a second unit reset upon completion. When the audio unit returns to normal mode, the software upgrade is complete. Page 1317 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Page 4023 1. NOTE: The main control cover gasket is a reusable type. Inspect the gasket for damage. Install a new gasket as necessary. Install the main control cover gasket. 2. NOTE: Install studs in locations 3 and 11. Install the main control cover. ^ Tighten to 13 Nm (10 ft. lbs.), in sequence shown. 3. Using a small amount of pipe sealant on the threads, install the transaxle drain plug. ^ Tighten to 27 Nm (20 ft. lbs.). Page 4231 4. Press out the bearing cups. ^ Rotate the driveshaft 180 degrees and repeat. 5. To assemble, reverse the disassembly procedure. Page 969 Page 4104 Shift Interlock: Description and Operation Shift Interlock System The shift interlock system prevents the gear shift lever from being moved out of the PARK (P) position. The ignition switch must be in the ON position and the brake pedal depressed to move the gearshift lever out of the PARK position. The brake pedal position is detected by the Brake Pedal Position (BPP) switch. The manual override button will mechanically bypass the electronic portion of the shift interlock system and allow the gearshift lever to be moved out of the PARK position. The manual override button is part of the gearshift lever assembly. To override the brake shift interlock, remove the tethered cap on the gear shift bezel with a small screwdriver. With the brake pedal depressed, insert a small screwdriver into the access hole, press down and pull the gear shift lever out of PARK. Page 863 062005A 2004-2005 1.1 Hrs. Explorer/Mountaineer: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2006 Explorer/Mountaineer: 1.3 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 F-150: Replace 0.5 Hr. Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2006 Escape, 0.8 Hr. 2005-2006 Mariner: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Five 1.3 Hrs. Hundred/Montego: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2005-2007 Freestyle: 0.7 Hr. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR 31012AL, 31012AT) DEALER CODING CONDITION BASIC PART NO. CODE 15K864 42 Disclaimer Page 5837 Air Bag Control Module: Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Capacity Specifications Fluid - A/T: Capacity Specifications Fluid Capacity....................................................................................................................................... ..........................................................9.5L (10 quarts) Page 4961 Page 4802 Fuse: Locations Battery Junction Box Page 4091 Symbols Part 4 Locations View 151-3 (Engine Compartment, 1 Of 2) Page 640 P1501 Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE WINDOW GLASS Removal and Installation 1. Open the liftgate window glass. 2. Remove the 2 liftgate window glass nut access covers. Page 6635 Hood Latch: Service and Repair Hood Latch and Components - Exploded View HOOD LATCH AND COMPONENTS - EXPLODED VIEW Removal and Installation 1. For additional information, refer to the procedures. Page 6577 Disclaimer Technical Service Bulletin # 06-9-2 Date: 060515 Audio System - Front Door Speaker Buzzing TSB 06-9-2 05/15/06 SPEAKER BUZZ - FRONT DOOR SPEAKERS ONLY FORD: 2005-2006 Escape Hybrid, Escape MERCURY: 2005-2006 Mariner 2006 Mariner Hybrid ISSUE Some 2005-2006 Escape, Escape Hybrid, Mariner, and 2006 Mariner Hybrid vehicles may exhibit a buzz from the front door speakers. This may be due to the resonant characteristics of the door vapor barrier (poly shield), or in some cases loose speaker mounting hardware. ACTION Use the following Service Procedure to resolve buzz from front door speaker. SERVICE PROCEDURE 1. Refer to Workshop Manual (WSM), Section 501-05 for door panel removal. 2. Remove both front door poly shields and operate radio to verify buzz is eliminated. If buzz is still present, go to Step 3. If buzz is eliminated, replace both front poly shields. Be sure to take care that the adhesive sections make full contact with the inner door panel and not the speaker 3. Verify speaker fasteners are properly torqued to 17 lb-in (1.9 N.m). If buzz is still present this TSB does not apply and refer to WSM for additional diagnostics. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 060902A 2005-2006 Escape, 0.7 Hr. Escape Hybrid, Mariner, Mariner Hybrid: Replace Vapor Barriers On Both Front Doors Includes Time To Perform Diagnosis Outlined In Procedure (Do Not Use With 23943A, 23943AT, 18808AF, 18808AFT) DEALER CODING CONDITION Page 1007 Description and Operation EGR Control Module: Description and Operation EGR SYSTEM MODULE (ESM) Overview EGR System Module (ESM) The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional DPFE system, however the various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a traditional DPFE system. The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional tests that monitor various aspects of the EGR system operation. First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405 P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403). NOTE: EGR normally has large amounts of water vapor that are the result of the engine combustion process. During cold ambient temperatures, under some circumstances, water vapor can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to prevent MIL illumination for temporary freezing, the following logic is used. If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines that the malfunction is no longer present, the EGR system will be enabled and normal system operation will be restored. If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the malfunction has been detected on 2 consecutive driving cycles. After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is evaluated to determine the amount of EGR system restriction. If the differential pressure is below a calibrated threshold, a low flow malfunction is indicated (P0401/P0406). Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero requested EGR flow to carry out the high flow check. If the differential pressure exceeds a calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR valve seat (P0402). If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles for the EGR monitor to be set to a ready condition. Window Adjust Switch Power Window Switch: Locations Window Adjust Switch View 151-23 (Right Front Door) Locations View 151-12 (Dash Panel) Diagrams Page 940 Page 1532 Impact Sensor: Diagrams Side Impact Sensor Page 5708 Removal and Installation 1. Recover the refrigerant. 2. Loosen the nut and disconnect the evaporator inlet line fitting. - Remove and discard the O-ring. - To install, tighten to 10 Nm (89 lb-in). 3. Disconnect the orifice evaporator inlet line spring lock coupling and remove the orifice evaporator inlet line. 4. NOTE: New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Charge and leak test the refrigerant system. Page 6506 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 4898 Relay Box: Locations Battery Junction Box System Diagnosis P073x Page 7792 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 5547 Blower Motor Resistor Page 6136 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 (ECU), 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 Page 6643 Page 6908 Page 1347 Crankshaft Position Sensor: Diagrams Page 5399 Page 7624 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 768 P2066 Removal and Installation Spark Plug: Service and Repair Removal and Installation SPARK PLUGS Exploded View Removal 1. Disconnect the battery ground cable. 2. Disconnect the ignition coil electrical connectors. 3. Remove the bolts and the ignition coils. 4. NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. Remove the spark plugs. Installation Lower, Front Transmission Mount: Service and Repair Lower, Front Transaxle Support Insulator-Lower, Front Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the LH splash shield. Service and Repair Headlamp Dimmer Switch: Service and Repair Steering Column Multifunction Switch Removal and Installation CAUTION: Do not remove the ignition lock cylinder and the ignition switch at the same time or damage to the column may result. 1. Remove the clockspring. Page 540 P1268 Page 5868 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 6966 Symbols Part 2 Page 4911 Relay Box: Application and ID Battery Junction Box Page 1291 View 151-25 (Liftgate) Page 7643 A5-A8 Fuel Pump Module and Reservoir Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 1030 Page 4584 Brake Rotor/Disc: Service and Repair Disc Removal and Installation, Rear Brake Disc Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the brake pads. 3. Remove the brake disc. 4. If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole access plug and retract the parking brake shoe and lining by rotating the adjuster. 5. To install, reverse the removal procedure. ^ Adjust the parking brake shoe and lining, if necessary. Page 6311 A2-A4 Page 4713 Smart Junction Box Relay Box: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Heated Seat Module, Passenger Side Front Page 2973 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. Description and Operation Vehicle Lifting: Description and Operation JACKING WARNING: - Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. Failure to follow these instructions may result in personal injury. - Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. Failure to follow these instructions may result in personal injury. - Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. Failure to follow these instructions may result in personal injury. CAUTION: The service jack provided with the vehicle is only intended to be used in an emergency for changing a deflated tire. Never use the service jack to hoist the vehicle for any other service. Refer to the Owner Guide when using the jack supplied with the vehicle. Jacking Points - Front Jacking Points - Front 1. The front jacking point is at the bolt head of the lower control arm. Jacking Points - Rear Jacking Points - Rear 1. The rear jacking points are located on the rear trailing arms. LIFTING Lifting Points Page 5939 Page 2938 Page 7717 Page 962 Throttle Plate Controller Check Operation The purpose of the TPPC is to maintain the throttle position at the desired throttle angle. It is a separate chip embedded in the PCM. The desired angle is communicated from the main CPU via a 312.5 Hz duty cycle (DC) signal. The TPPC interprets the duty cycle signal as follows: Less than 5% - Out of range, limp home default position. - Greater than or equal to 5% but less than 6% - Commanded default position, closed. - Greater than or equal to 6% but less than 7% - Commanded default position. Used for key-on, engine off. - Greater than or equal to 7% but less than 10% - Closed against hard-stop. Used to learn zero throttle angle position (hard-stop) after key-up. - Greater than or equal to 10% but less than or equal to 92% - Normal operation, between 0 degrees (hard-stop) and 82 degrees, 10% duty cycle equals 0 degrees throttle angle, 92% duty cycle equals 82 degrees throttle angle. - Greater than 92% but less than or equal to 96% - Wide Open Throttle, 82 to 86 degrees throttle angle. - Greater than 96% but less than or equal to 100% - Out of Range, limp home default position. The desired angle is relative to the hard-stop angle. The hard-stop angle is learned during each key-up process before the main CPU requests the throttle plate be closed against the hard-stop. The output of the TPPC is a voltage request to the H-driver (also in PCM). The H driver is capable of positive or negative voltage to the electronic throttle body motor. Page 4600 Brake Shoe: Service and Repair Brake Shoes Material Removal and Installation 1. NOTE: If new rear brake shoes and linings are being installed, resurface the brake drums to remove glazing and to provide an equal friction surface from side-to-side. Resurfacing also corrects out-of-round and bell conditions. Remove the brake drum. 2. Remove the parking brake lever clip. 3. Remove the 2 brake shoe retaining clips and the 2 pins. 4. Remove the upper return spring. 5. Remove the self-adjuster assembly. 6. Remove the lower return spring. 7. Remove the parking brake actuator lever. 8. Remove the rear brake shoes. ^ Apply silicone grease to the brake shoe contact points on the backing plate. 9. Remove the self-adjuster spring and lever. 10. Remove the pivot pin. 11. To install, reverse the removal procedure. ^ Adjust the rear brake shoes. Page 7275 View 151-25 (Liftgate) Page 4995 Locations View 151-7 (Engine, front) Page 65 P0120 - P0124: Testing and Inspection P0123 P0123 (Part 1) P0123 (Part 2) Page 515 P1236 Page 7306 Special Tool(s) Page 7634 Horn: Description and Operation HORN There are 2 separate conditions that can cause the horn to sound. The horn will sound if the driver presses the horn switch and when the vehicle security system is armed. The horn system uses the smart junction box (SJB) to provide voltage to the horns, while the horn switch or the SJB can provide the ground to engage the horn relay. The horn switch is integrated into the air bag. For the removal and installation of the air bag, refer to Air Bag Systems. Page 5284 Front Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Locations View 151-8 (Engine, rear) Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER Escape Is Shown, Mariner Is Similar (Part 1) Page 7659 Symbols Part 3 Diagram Information and Instructions Horn: 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 8026 Wiper Motor: Testing and Inspection WINDSHIELD WIPER MOTOR Use a Starter, Alternator, Battery, Regulator and Electrical (SABRE) tester to test the wiper motor on the vehicle. To test the wiper motor, disconnect 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 tester to the battery negative (-) post. Connect the (3) red lead from the SABRE to the wiper motor (4) common brush terminal (terminal 3). Test the low-speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low-speed brush terminal (terminal 2) and measure the current draw. If the current draw is greater than 3.5 amperes, install a new windshield wiper motor. Test the high-speed mode by connecting a cable from the battery positive (+) post to the (7) high-speed brush terminal (terminal 1) and measure the current draw. If the current draw is greater than 5.5 amperes, install a new wiper motor. Page 6939 Paint: Application and ID Paint Code Sticker Location PAINT CODE STICKER LOCATION Vehicle Certification (VC) Label Locator The VC label is located on the left-hand door jamb. P0040 P0040 Page 864 View 151-18 (Full Body, Right Rear - 2 Of 2) Door Speaker Speaker: Service and Repair Door Speaker DOOR SPEAKER Removal and Installation All Speakers 1. Remove the door trim panel. Front Door Tweeter Speaker 2. Release the pin-type retainer and remove the front door tweeter speaker. Front or Rear Door Speaker 3. Remove the 4 speaker screws and the speaker. - Disconnect the electrical connector. All Speakers 4. To install, reverse the removal procedure. Page 2541 Underbody Catalyst The underbody catalyst is located afier the light off catalyst. The underbody catalyst may be in-line with the light off catalyst or the underbody catalyst may be common to 2 light off catalysts forming a Y pipe configuration. Three-Way Catalytic Converter The 3-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 NO. The 3-way conversion can be best accomplished by always operating the engine air fuel/ratio at or close to stoichiometry. Exhaust Manifold Runners The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust manifolds and exhaust manifold runners depends on the engine configuration and number of cylinders. Exhaust Pipes Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the engine exhaust manifold through the catalytic converter and the muffler. 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. For information on the HO2S refer to PCM Inputs in this section. Muffler Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase the life of the product. The muffler reduces the level of noise produced by the engine and also reduces the noise produced by exhaust gases as they travel from the catalytic converter to the atmosphere. Initial Inspection and Diagnostic Overview Driver/Vehicle Information Display: Initial Inspection and Diagnostic Overview Principles of Operation PRINCIPLES OF OPERATION The message center electronic functions use both hardwired and controller area network (CAN) circuits to transmit and receive information. It is very important to understand: - where the input (command) originates. - all the information (messages) necessary in order for a feature to operate. - which module(s) receive(s) the input or command message. - does the module which received the input (message) control the output of the feature, or does it output a message over the CAN circuits to another module? - which module controls the output of the feature. Display Information The display modes are: information - setup - system check - warning - temporary alert - display off Using the message center, various information can be selected and reset by pressing the following buttons: SET - INFO The select display and the reset display time-out and default to the information display mode. The temporary alert display interrupts 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: compass - average fuel economy - distance to empty - instantaneous fuel economy - fuel available - units (US/metric) - language - display off Setup Displays The setup displays are timed modes and default back to the information display function. The setup display modes are: language - units (US/metric) - system check System Check The system check display is a sub-routine of the setup menu. These sub-routines 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% - charging system - door ajar - brake fluid level - check headlamps - check brake lamps - check front turn lamps - check parking lamps - fuel level - miles to empty - emission system - 4x4 OK Warning Messages Page 5096 Locations View 151-7 (Engine, front) Page 4127 6. Install the upper shift lever trim ring. ^ To install the upper shift lever trim ring, orient the thick tab on the driver side front of the shifter and press into place. 7. Move the shifter through all gears from PARK to DRIVE several times making sure that the screw is not too tight. Page 126 P0182 Page 5181 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Page 7953 Rear Door Window Glass: Service and Repair Rear Door Window Glass REAR DOOR WINDOW GLASS Removal and Installation 1. Remove the rear door glass top run. 2. Remove the rear door window glass. 3. To install, reverse the removal procedure. - Cycle the rear door window glass to make sure it is engaged correctly. Page 3218 Pressure Feedback Exhaust Sensor: Description and Operation Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor The tube mounted DPFE sensor is identical in operation as the larger plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose connections are marked on the side of the sensor. Page 2482 Heater Core: Service and Repair HEATER CORE Removal and Installation NOTE: If a heater core leak is suspected, the heater core must be leak tested before the heater core is removed. 1. Drain the engine coolant. 2. Release the 2 clamps and disconnect the 2 heater hoses from the heater core. 3. Remove the instrument panel. Refer to: Body and Frame, Interior Moulding/Trim, Dashboard/Instrument Panel, Service and Repair, Removal and Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Removal and Installation 4. Remove the screw and the temperature blend door lever. 5. Remove the 3 screws and the heater core cover. 6. Remove the heater core from the housing. 7. NOTE: - Make sure the temperature blend door actuator and switch are in the correct position when installing the temperature blend door lever. - Lubricate the coolant hoses with plain water only if needed. To install, reverse the removal procedure. Fill and bleed the engine cooling system. Testing and Inspection Micro ISO Relay: Testing and Inspection Page 938 Page 2978 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 Page 6962 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 4305 Page 845 Page 473 P1127 Page 3700 Crankshaft Position Sensor: Diagrams Page 5415 3. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. Page 6277 to show the status of an event that has just happened and disappears after a few seconds. The warning display interrupts the current display until cleared or reset by the driver. Message Center General Displays The message center display is a 2 row by 12 character LCD display. The display is controlled by a 2 button switch module that includes INFO and SET buttons outside of the instrument cluster. The information displayed in the message center display falls into 4 main categories: jump start mode - info - warnings - temporary alerts Message Center Information Displays The INFORMATION DISPLAY mode is entered by pressing the INFO button. Subsequent presses of the INFO button scroll through the menu features of the information display. System Check When the SET FOR SYSTEM CHECK information is currently displayed, pressing the SET button leads the instrument cluster to initiate the system check function. The system check function provides the driver with the current status of certain vehicle functions. The status of each function is displayed sequentially on the message center. The driver has the ability to scroll through the system check displays by repeatedly pressing the SET button, or the display automatically scrolls at 2 seconds time out per display. The system check function can be terminated at any time by pressing any message center switch other than the SET button. Warning Indicators and Messages Warning Indicators And Messages The warning messages have precedence over all other messages. Every warning message is displayed. The messages can be single cycle, non-resettable, or repetitive. The instrument cluster indicators that are illuminated when a fault occurs and the message that follows are shown in the table. Warning Messages The instrument cluster messages that are displayed when a fault occurs are shown in the table. The warning messages continue to cycle in order until the vehicle condition causing the warning is corrected, until the ignition switch is turned to the OFF position, or until the message center is reset while the warning is displayed. A warning is removed from the display when the message center is reset unless the warning is non-resettable. A repeated warning message is removed from the display when the message center is reset and displays again after 10 minutes if the warning condition is not corrected. The single cycle warning message is removed from the display when the message center is reset and is not displayed again until the next ignition cycle. Multiple messages are cycled through in a fixed order with a display of 4 seconds for each warning. No other display modes are allowed while a warning message is displayed. Inspection and Verification Page 6342 Torque Specifications Page 2998 Data Link Connector (DLC) C251 Four-Wheel Drive (4WD) Control Module C3253 Page 1782 Cabin Air Filter: Description and Operation Page 2579 Electronic Throttle Monitor Operation (Part 1) Electronic Throttle Monitor Operation (Part 2) Accelerator and Throttle Position (TP) Sensor Inputs Accelerator Pedal Position (APP) Sensor Check: Accelerator Pedal Position (APP) Sensor Check Throttle Position (TP) Sensor Check: Throttle Position (TP) Sensor Check Throttle Plate Position Controller (TPPC) Outputs Page 6652 Page 2809 Crankshaft Position Sensor: Diagrams Service and Repair Valve Guide: Service and Repair Valve Guide Inner Diameter 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specifications, install a new cylinder head assembly. Page 3657 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Page 7441 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 5328 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 3057 Page 7866 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 Brake Pedal Position (BPP) Switch Brake Switch (Cruise Control): Description and Operation Brake Pedal Position (BPP) Switch BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Smart Junction Box Fuse: Application and ID Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 2947 Mechanical Returnless Fuel Pump Module (FPM) Page 5240 Using the special tool, separate the tie-rod from the wheel knuckle. 6. Remove the lower ball joint pinch bolt nut and the pinch bolt. 7. Remove the anti-lock brake system (ABS) wheel speed sensor bolt and position the sensor aside. 8. Separate the lower ball joint from the wheel knuckle. 9. Remove the 2 strut-to-knuckle nuts, bolts and the wheel knuckle. Installation 1. Position the wheel knuckle and install the 2 strut-to-knuckle bolts and nuts. ^ Tighten to 115 Nm (85 ft. lbs.). 2. Position and align the ball joint stud into the wheel knuckle. 3. Install the lower ball joint pinch bolt and nut. ^ Tighten to 70 Nm (52 ft. lbs.). 4. Install the ABS wheel speed sensor and the bolt. ^ Tighten to 9 Nm (80 inch lbs.). 5. Position the tie rod-end into the wheel knuckle and install the tie-rod end-to-knuckle nut and a new cotter pin. ^ Tighten to 55 Nm (41 ft. lbs.). 6. Using the special tool, insert the halfshaft into the wheel hub. 7. Install the wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 8. Install the brake disc. 9. Check and, if necessary, align the front end. Page 7432 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 1495 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Page 4190 8. Remove the tripod joint. 9. Remove the remaining snap ring from the front drive halfshaft. 10. Remove the inner CV boot from the front drive halfshaft. 11. Remove the 2 outer CV boot clamps and slide the outer CV joint boot back out of the way, exposing the outer CV joint. 12. If installing the original outer CV joint, mark the outer CV joint and front drive halfshaft to be sure of correct installation. 13. Using a soft-face hammer, separate the outer CV joint by gently tapping it off the front drive halfshaft. 14. Remove and discard the front drive halfshaft bearing retainer circlip. 15. Remove the outer CV boot from the front drive halfshaft. Assembly NOTE: Verify that all the components are clean and free of foreign material before assembly. Page 958 Electronic Throttle Body (ETB) And Accelerator Pedal Assembly The ETC strategy uses pedal position sensors as an input to determine the driver demand. 1. There are 3 pedal position signals required for system monitoring. APP1 has a negative slope (increasing angle, decreasing voltage) and APP2 and APP3 both have a positive slope (increasing angle, increasing voltage). During normal operation APP1 is used as the indication of pedal position by the strategy. 2. There are 2 VREF circuits, 2 signal return circuits, and 3 signal circuits (a total of 7 circuits and pins) between the PCM and the APP sensor assembly. 2 reference voltage circuits (5 volts). - 2 signal return (ground) circuits. - APP1 voltage with negative voltage slope (5-0 volts). - APP2 voltage with positive voltage slope (0-5 volts). - APP3 voltage with positive voltage slope (0-5 volts). 3. The pedal position signal is converted to pedal travel degrees (rotary angle) by the PCM. The software then converts these degrees to counts, which is the input to the torque based strategy. 4. The 3 pedal position signals make sure the PCM receives a correct input even if 1 signal has a fault. The PCM determines if a signal is incorrect by calculating where it should be, inferred from the other signals. A value will be substituted for an incorrect signal if 2 of the 3 signals are incorrect. Electronic Throttle Control (ETC) System Strategy Page 1902 OPERATION DESCRIPTION TIME 090404A 2005-2009 Escape, 0.5 Hr. Mariner, Escape Hybrid, 2006-2009 Mariner Hybrid: Clean Bolt Contact Surfaces, Includes Time To Check And Adjust PTU Fluid Level DEALER CODING CONDITION BASIC PART NO. CODE 7034 24 Disclaimer Page 4537 13. To install, reverse the removal procedure. Page 807 P2128 Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: Customer Interest Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. System Diagnosis P1299 Page 1098 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6268 Page 5989 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 3058 Mechanical Specifications Axle Shaft Assembly: Mechanical Specifications Page 894 Page 2099 Special Tool(s) Removal NOTE: LH is shown, RH is similar. 4WD vehicles 1. Remove the wheel knuckle. FWD vehicles 2. Remove and discard the wheel hub nut. 3. Remove the Anti-Lock Brake System (ABS) wheel speed sensor ring. All vehicles Page 6024 2. Lower the height adjuster and remove the upper bolt. - To install, tighten to 47 Nm (35 lb-ft). 3. NOTE: Note the position of the lower locator tab for installation. Raise the height adjuster and remove the lower bolt and height adjuster. To install, tighten to 47 Nm (35 lb-ft). 4. To install, reverse the removal procedure. 5. Check the active restraint system for correct operation. Page 5812 Air Bag: Description and Operation Driver Air Bag Module NOTE: The driver air bag (soft pack) and steering wheel can be serviced separately or as an assembly. - In the event of an air bag deployment, the air bag (soft pack) and steering wheel must be serviced as an assembly. The driver air bag module: is installed new as an assembly. - is mounted in the center of the steering wheel. - will deploy upon receiving a flow of current from the restraints control module (RCM). Passenger Air Bag Module The passenger air bag module: is installed new as an assembly. - is mounted in the passenger side of the instrument panel. - will deploy upon receiving a flow of current from the restraints control module (RCM). - is single stage unit on Escape Hybrid vehicles. - is a dual stage unit on Escape and Mariner vehicles. Safety Canopy Module Vehicles With Moon Roof Vehicles Without Moon Roof WARNING: Anytime the safety canopy has deployed, the headliner, and all A-, B- and C- upper trim panels and attaching hardware must be replaced along with any other damaged components and hardware. Failure to do so can result in personal injury in the event of a safety canopy deployment. NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. The side air curtain module or safety canopy: is installed as an assembly. Restraints - Control Module DTCs & Associated Fault PIDs Air Bag 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 6463 Symbols Part 2 Page 6755 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 7620 Symbols Part 4 Page 3418 Fuel Injector: Description and Operation Fuel Injectors For information on the fuel injectors, refer to the description of the Fuel Systems Locations Page 1437 Transmission Position Switch/Sensor: Service and Repair Transmission Range (TR) Sensor Special Tool(s) Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the battery and tray. 3. Remove the Transmission Range (TR) sensor. 1 Disconnect the TR sensor electrical connector. 2 Remove the TR sensor retaining bolts. 3 Remove the TR sensor. Installation 1. NOTE: Make sure the transaxle is in the NEUTRAL position. Install the TR sensor and loosely install the bolts. Page 1998 Differential Pressure Feedback EGR (DPFE) System Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) System DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SYSTEM Differential Pressure Feedback EGR (DPFE) System Operation The differential pressure feedback EGR system consists of a differential pressure feedback EGR sensor, EGR vacuum regulator (EVR) solenoid, EGR valve, orifice tube assembly, powertrain control module (PCM), and connecting wires and vacuum hoses. Operation of the system is as follows: 1. The DPFE system receives signals from the engine coolant temperature (ECT) sensor or cylinder head temperature (CHT) sensor, intake air temperature (IAT) sensor, throttle position (TP) sensor, mass air flow (MAF) sensor, and crankshaft position (CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable, and running at a moderate load and RPM before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle, or whenever a failure is detected in an EGR component or EGR required input. 2. The PCM calculates the desired amount of EGR flow for a given engine condition. It then determines the desired pressure drop across the metering orifice required to achieve that flow and outputs the corresponding signal to the EVR solenoid. 3. The EVR solenoid receives a variable duty cycle signal (0 to 100%). The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. 4. The increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold. 5. Exhaust gas flowing through the EGR valve must first pass through the EGR metering orifice. With one side of the orifice exposed to exhaust backpressure and the other to the intake manifold, a pressure drop is created across the orifice whenever there is EGR flow. When the EGR valve closes, there is no longer flow across the metering orifice and pressure on both sides of the orifice is the same. The PCM constantly targets a desired pressure drop across the metering orifice to achieve the desired EGR flow. 6. The DPFE sensor measures the actual pressure drop across the metering orifice and relays a proportional voltage signal (0 to 5 volts) to the PCM. The PCM uses this feedback signal to correct for any errors in achieving the desired EGR flow. Steering - Front End Rattle Noise Turning On Bumps Power Steering Line/Hose: All Technical Service Bulletins Steering - Front End Rattle Noise Turning On Bumps TSB 06-17-3 09/04/06 STEERING NOISE - CLUNK/RATTLE FORD: 2005-2007 Escape MERCURY: 2005-2007 Mariner This article supersedes TSB 05-25-9 to update the vehicle model years. ISSUE Some 2005-2007 Escape and Mariner vehicles may exhibit a single or multiple clunk/rattle noise from the front end. This noise typically occurs with the front wheels turned while hitting a bump such as when turning into a driveway. It is usually more noticeable with hot engine and ambient air temperatures, and may easily be mistaken for loose sheet metal or a loose suspension/underhood component. The cause of this noise is an audible hydraulic pressure spike in the power steering system. ACTION Install a new power steering return line which contains an internal orifice to reduce the pressure spike. SERVICE PROCEDURE 1. Remove the power steering reservoir cap. 2. Using a suitable suction device, remove the power steering fluid from the reservoir. 3. Disconnect the power steering return hose from the reservoir by loosening the constant tension clamp. 4. Remove and discard the lower return line hose clamp, then remove the hose. 5. Install the new return line with the crimped band away from the reservoir. The pre-installed constant tension clamp will retain the reservoir end of the hose. 6. Install and tighten the screw clamp on the lower end of the hose. 7. Refill the system with Mercon® or Mercon(R)-V fluid and purge the air as described in Section 211-00 of the Workshop Manual. NOTE DO NOT FILL WITH TYPE-F FLUID. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061703A 2005-2007 Escape/Mariner: 0.5 Hr. Replace Power Steering Return Line (Do Not Use With 3713AE) DEALER CODING CONDITION BASIC PART NO. CODE 3A713 42 Page 2664 Fuel Level Sensor: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 2700 Oxygen Sensor: Harness Locations View 151-8 (Engine, rear) Page 2195 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Pulley Special Tool(s) Material Removal 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: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the accessory drive belt. 3. Remove the valve cover. Page 2531 Thermostat Housing: Service and Repair Thermostat Housing-2.3L NOTE: The thermostat and thermostat housing are serviced as an assembly. Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Drain the cooling system. 3. Remove the accessory drive belt. 4. Disconnect the heater hose at the thermostat housing. 5. Disconnect the lower radiator hose at the thermostat housing. 6. Remove the 3 bolts, thermostat housing and gasket. ^ To install, tighten to 10 Nm (89 inch lbs.). 7. To install, reverse the removal procedure. ^ Clean and inspect the gasket, replace if necessary. 8. Fill and bleed the cooling system. Page 1540 1. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the B-pillar sheet metal. 2. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 3. Connect the side impact sensor electrical connector. 4. Install the B-pillar trim panel. 5. Repower the system. Page 6288 A1-A2 Normal Operation The message center display is located in the center of the instrument cluster. The messages are dependant on various vehicle inputs. Possible Causes - instrument cluster - message center switch(es) Test B: The Turn Signal On Warning Display Is Inoperative PINPOINT TEST B: THE TURN SIGNAL ON WARNING DISPLAY IS INOPERATIVE B1-B3 Normal Operation The turn signal on reminder warning feature alerts the operator that one of the turn signals has been on for 1/2 mile or more. Possible Causes - turn signals - circuitry - instrument cluster Test C: The Message Center Switch Does Not Operate Correctly Page 3392 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Page 7486 900 ....................................................................................................................................................... ........................ Above door trim panel and headliner Symbols and Wire Color Code Identification Symbols Part 1 A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle 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 only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Page 253 P0355 - P0359: Testing and Inspection P0358 P0358 (Part 1) P0358 (Part 2) Page 7838 Turn Signal Lamp: Diagrams Park/Turn Lamp Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Page 7686 Symbols Part 3 Page 1937 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 the 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. P1512 P1512 Specifications Wheel Fastener: Specifications 5 Wheel nuts. Tighten the wheel nuts in a star pattern. Tighten to ............................................................................ .............................................................................................................. 133 Nm (98 ft. lbs.) Page 2000 Passenger Air Bag Module View 151-12 (Dash Panel) Page 1520 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 7534 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 2805 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 2578 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: Description and Operation EGR Control Module: Description and Operation EGR SYSTEM MODULE (ESM) Overview EGR System Module (ESM) The ESM is an updated DPFE EGR system. It functions in the same manner as the conventional DPFE system, however the various system components have been integrated into a single component called the ESM. The flange of the valve portion of the ESM bolts directly to the intake manifold with a metal gasket that forms the measuring orifice. This arrangement increases system reliability, response time, and system precision. By relocating the EGR orifice from the exhaust to the intake side of the EGR valve, the downstream pressure signal measures manifold absolute pressure (MAP). The system provides the PCM with a differential DPFE signal, identical to a traditional DPFE system. The delta pressure feedback EGR monitor is comprised of a series of electrical tests and functional tests that monitor various aspects of the EGR system operation. First, the DPFE sensor input circuit is checked for out of range values (P1400/P0405 P1401/P0406). The EVR output circuit is checked for opens and shorts (P1409/P0403). NOTE: EGR normally has large amounts of water vapor that are the result of the engine combustion process. During cold ambient temperatures, under some circumstances, water vapor can freeze in the DPFE sensor, hoses, as well as other components in the EGR system. In order to prevent MIL illumination for temporary freezing, the following logic is used. If an EGR system malfunction is detected below 0°C (32°F), only the EGR system is disabled for the current driving cycle. A DTC is not stored and the I/M readiness status for the EGR monitor will not change. The EGR monitor will, however, continue to operate. If the EGR monitor determines that the malfunction is no longer present, the EGR system will be enabled and normal system operation will be restored. If an EGR system malfunction is detected above 0°C (32°F), the EGR system and the EGR monitor is disabled for the current driving cycle. A DTC is stored and the MIL is illuminated if the malfunction has been detected on 2 consecutive driving cycles. After the vehicle has warmed up and normal EGR rates are being commanded by the PCM, the low flow check is carried out. Since the EGR system is a closed loop system, the EGR system will deliver the requested EGR flow as long as it has the capability to do so. If the EVR duty cycle is very high (greater than 80% duty cycle), the differential pressure indicated by the DPFE sensor is evaluated to determine the amount of EGR system restriction. If the differential pressure is below a calibrated threshold, a low flow malfunction is indicated (P0401/P0406). Finally, the differential pressure indicated by the DPFE sensor is also checked at idle with zero requested EGR flow to carry out the high flow check. If the differential pressure exceeds a calibrated limit, it indicates a stuck open EGR valve or debris temporarily lodged under the EGR valve seat (P0402). If the inferred ambient temperature is less than 0°C (32°F), or greater than 60°C (140°F), or the altitude is greater than 8,000 feet (BARO less than 22.5 in-Hg), the EGR monitor cannot be run reliably. In these conditions, a timer starts to accumulate the time in these conditions. If the vehicle leaves these extreme conditions, the timer starts to decrement, and, if conditions permit, will attempt to complete the EGR flow monitor. If the timer reaches 800 seconds, the EGR monitor is disabled for the remainder of the current driving cycle and the EGR Monitor I/M Readiness bit will be set to a ready condition after one such driving cycle. Vehicles will require 2 such driving cycles for the EGR monitor to be set to a ready condition. System Diagnosis P1336 Page 82 P0136 Page 2908 Crankshaft Position Sensor: Diagrams Locations View 151-13 (Behind Dash Panel) Page 2116 ACTION Review the neutral tow application chart (Figure 1) and order the kit, if applicable. Reprogramming of various modules may be required for some installations. Installation instructions are included with the kit. Page 5951 5. NOTE: The RCM has been removed for clarity. Connect the large RCM electrical wiring 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. 6. Position back the carpet on the LH and RH tunnel to its original position. 7. Install the lower LH center instrument panel finish panel. 8. Repower the system. Page 7597 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Specifications Flex Plate: Specifications NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flexplate and tighten the bolts in the sequence shown in 3 stages. ^ Stage l: Tighten to ............................................................................................................................... ..................................... 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten to ........................................................................................................................... ........................................ 80 Nm (50 ft. lbs.). ^ Stage 3: Tighten to ........................................................................................................................... ...................................... 112 Nm (83 ft. lbs.). Page 5835 ^ 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. A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 6457 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. Smart Junction Box Fuse Block: Locations Smart Junction Box Note: The fuse panel is located on the right-hand side of the center console, by the instrument panel. Remove the panel cover to access the fuses. Page 5475 4. Using the special tools, remove the wheel hub. 5. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 6. Remove the wheel bearing snap ring from the wheel knuckle. FWD vehicles 7. Using the special tools, remove the wheel bearing from the wheel knuckle. 4WD vehicles 8. Using the special tools, press the wheel bearing race from the wheel knuckle. Installation All vehicles Locations View 151-7 (Engine, front) Page 7535 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 Driveshaft Indexing Drive/Propeller Shaft: Service and Repair Driveshaft Indexing Driveshaft Indexing NOTE: If indexing the driveshaft does not eliminate the vibration, balance the driveshaft. Refer to Driveshaft Runout and Balancing. 1. With the vehicle in NEUTRAL, position it on a hoist. 2. CAUTION: Do not reuse the CV joint bolts and washers. Install new bolts and washers or damage to the vehicle may occur. Remove and discard the 6 front driveshaft-to-transfer case bolts and washers. 3. Rotate the flange 60 degrees. 4. Connect the front driveshaft and install the 6 new bolts and washers. ^ Tighten to 37 Nm (27 ft. lbs.). 5. CAUTION: Do not reuse the bolts and cap straps for the pinion yoke. Install new bolts and cap straps or damage to the vehicle may occur. Disconnect the rear driveshaft universal joint. ^ Discard the 4 bolts and the 2 cap straps. 6. Rotate the rear pinion 180 degrees. 7. Connect the rear driveshaft and install 4 new bolts and 2 new cap straps. ^ Tighten to 23 Nm (17 ft. lbs.). 8. Lower the vehicle and test drive. 9. Repeat the procedure if necessary. Page 5089 1. Refer to the Drift/Pull diagnostic flow chart (Figure 1). 2. Use procedures in TSB when adjusting alignment if directed by the diagnostic flow chart. Page 5940 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 4418 Removal NOTE: If the transfer case is leaking automatic transaxle fluid, install a new transfer case driven gear seal. 1. Remove the exhaust system crossover pipe. 2. Remove the 3 bolts and the transfer case heat shield. 3. Remove the front drive axle intermediate shaft. 4. Remove the transfer case RH halfshaft dust shield. 5. Remove the transfer case RH halfshaft oil seal. Installation 1. NOTE: Press the transfer case RH halfshaft seal until it is flush with the transfer case cover. Using the special tools, install the RH halfshaft seal. Diagrams Power Steering Pressure (PSP) Switch Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Switch POWER STEERING PRESSURE (PSP) SWITCH Typical Power Steering Pressure (PSP) Switch The PSP switch monitors the hydraulic pressure within the power steering system. The PSP switch is a normally closed switch that opens as the hydraulic pressure increases. The PCM provides a low current voltage on the PSP circuit. When the PSP switch is closed, this voltage is pulled low through the SIG RTN circuit. The PCM uses the input signal from the PSP switch to compensate for additional loads on the engine by adjusting the idle RPM and preventing engine stall during parking maneuvers. Also, the PSP switch signals the PCM to adjust the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 7016 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 3887 Symbols Part 3 Page 5291 Front Subframe: Service and Repair FRONT SUBFRAME Special Tool(S) Special Tool(s) Page 1124 Page 3012 G3-G4 Page 5700 Hose/Line HVAC: Service and Repair Condenser to Evaporator Line CONDENSER TO EVAPORATOR LINE Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the air conditioning (A/C) refrigerant. 3. Remove the front bumper cover. 4. Disconnect the high pressure cut-off switch electrical connector. 5. Remove the condenser to evaporator line bracket nut. - To install, tighten to 8 Nm (71 lb-in). 6. Disconnect the evaporator core spring lock coupling. 7. Remove the condenser to evaporator line peanut fitting nut and disconnect the line. - To install, tighten to 8 Nm (71 lb-in). 8. Remove the condenser to evaporator line. 9. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. To install, reverse the removal procedure. Evacuate, leak test, and charge the refrigerant system. Page 2295 Engine Oil Pressure: Testing and Inspection Oil Pressure Test 1. Disconnect and remove the oil pressure sensor from the engine. 2. Connect the Engine Oil Pressure Gauge to the oil pressure sender oil galley port. 3. Run the engine until normal operating temperature is reached. 4. Run the engine at the specified rpm and record the gauge reading. 5. The oil pressure should be within specifications. 6. If the pressure is not within specification, check the following possible sources: ^ insufficient oil ^ oil leakage ^ worn or damaged oil pump ^ oil pump screen cover and tube ^ excessive main bearing clearance ^ excessive connecting rod bearing clearance ^ chain tensioner leak Page 6157 Page 1423 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Steering - Improved Drift/Pull Diagnostics Alignment: By Symptom Steering - Improved Drift/Pull Diagnostics TSB 04-21-4 11/01/04 STEERING DRIFT/PULL - IMPROVED DIAGNOSTIC AND REPAIR PROCEDURE - SERVICE TIP FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some vehicles may exhibit a drift/pull to either the right or left. This condition may occur even if the alignment settings are within specifications. ACTION The following procedure is designed to supplement the Workshop Manual. It contains a more detailed description of the camber/caster adjustment, updated diagnostics to help determine cause and an updated camber adjustment procedure. SERVICE PROCEDURE Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 7550 Daytime Running 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. 97-1 Page 5574 Using the special tools, install the A/C clutch field coil. 3. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head. It must be correctly aligned during installation. Install the A/C clutch pulley. 4. Install the A/C clutch pulley snap ring with the bevel side out. 5. Place 1 nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch disc and hub assembly. Page 2267 Engine Oil: Fluid Type Specifications Engine Oil ................................................................................................................................................. SAE 5W-20 Premium Synthetic Blend Motor Oil System Diagnosis P1520 Page 3193 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater by providing the ground when the proper conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: Customer Interest Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 7606 Tires - Vibration Highway at Speeds Tires: Customer Interest Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Page 7494 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 5417 Special Tool(s) Removal NOTE: LH is shown, RH is similar. 4WD vehicles 1. Remove the wheel knuckle. FWD vehicles 2. Remove and discard the wheel hub nut. 3. Remove the Anti-Lock Brake System (ABS) wheel speed sensor ring. All vehicles Diagrams Page 6857 1. Without pulling the headliner down beyond its natural hanging rest position, carefully inspect the structural foam blocks mounted at the passenger and drivers side front corners on the top of the headliner to see if they have one (1) or two (2) indentations. See Figure 2. ^ If the blocks have only one (1) indentation, proceed to DISASSEMBLY FOR MODIFICATION. ^ If the blocks have two (2) indentations, no modification is required. Proceed to ASSEMBLY. DISASSEMBLY FOR MODIFICATION 1. Remove the interior lamp lens. 2. Remove the two (2) screws and the interior lamp, then disconnect the electrical connector. 3. Proceed to STRUCTURAL FOAM BLOCK MODIFICATION. STRUCTURAL FOAM BLOCK MODIFICATION 1. Using fender covers, seat covers or suitable rags, cover the defroster and instrument panel ducts so chips cannot fall into the heater plenum while drilling. 2. Install a drill stop or apply suitable tape onto the drill bit 140 mm (5-1/2 in) from the end of the cutting portion of the bit (not from the threaded tip). See Figure 3. 3. CAUTION: The weight of the tool when positioned on the foam block increases the risk of headliner damage. Hold the headliner up when the tool is positioned on the foam block. Page 5258 Other Labor Operations) DEALER CODING CONDITION BASIC PART NO. CODE 5K483 24 Disclaimer Page 6095 Impact Sensor: Diagrams Side Impact Sensor Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Warning Indicator: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) Page 1574 and ECU) must be installed as an assembly. - To identify between a production OCS system and a service OCS system (OCS service kit), inspect the electronic control unit (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 the appropriate procedure. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Remove the passenger seat. 3. Disconnect the electrical connectors and wiring clips. 1 Disconnect the OCS ECU electrical connector. 2 Disconnect the pressure sensor electrical connector. 3 Release the 2 wiring clips on the wiring harness from the cushion pan. 4 If equipped with heated seats, disconnect the heated seat module electrical connector, release the wiring clip on the wiring harness from the cushion pan, and disconnect the 2 cushion element electrical connectors. 4. Remove the 4 seat cushion bolts retaining the seat cushion to the seat track. 5. 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. Remove the seat cushion and pan assembly. To aid in removal, recline the seat. Diagrams Page 7146 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. Page 3616 3. Squeeze the tabs and remove the accelerator cable from the bracket. 4. Remove the nuts and the accelerator cable-to-valve cover stud brackets. - To install, tighten to 10 Nm (89 lb-in). 5. Remove the accelerator cable grommet from the dash panel. 6. Remove the accelerator cable from the rubber plunger. 7. Position the plunger rearward and remove the cable from the accelerator pedal. - Remove the accelerator cable. 8. To install, reverse the removal procedure. Page 4362 Case: Service and Repair Transfer Case Vent Special Tool(s) General Equipment Material Removal 1. Remove the transfer case. 2. Using the slide hammer with a 3-jaw puller attachment, remove the transfer case tube. Installation Description and Operation Brake Switch - TCC: Description and Operation BRAKE PEDAL POSITION (BPP) SWITCH Typical Brake Pedal Position (BPP) Switch The BPP switch 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 pedal is applied. - BPP switch is hard wired to a module (ABS, LCM, or REM), the BPP signal is then broadcast over the data link to be received by the PCM. - BPP switch is hard wired to the anti-lock brake system (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 stop lamp circuit, if all stop lamp 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 stop lamp bulbs has failed. Service and Repair Body Control Module: Service and Repair SMART JUNCTION BOX (SJB) Removal and Installation 1. CAUTION: Prior to removal of the SJB, it is necessary to upload module configuration information to a diagnostic tool. This information needs to be downloaded into the new module once installed. Disconnect the battery. 2. Remove the floor console SJB cover. 3. Remove the transmission selector lever bezel from the floor console finish panel. 4. Apply the parking brake. 5. Remove the parking brake lever boot from the floor console finish panel. 6. Remove the floor console finish panel. Electrical - Wiring Harness Replacement Guidelines Wiring Harness: 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 6788 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 5286 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape Page 5818 Air Bag: Service and Repair Passenger Air Bag Module PASSENGER AIR BAG MODULE 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 deployment door 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 deployment door 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 deployment doors must be replaced, not repainted. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. 2. Open and lower the glove compartment door. 3. Disconnect the passenger air bag module electrical connector. 4. Remove the 4 passenger air bag module bolts. Page 5276 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 3464 Page 7515 A4-A6 Page 7263 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Page 5595 Compressor Clutch Relay: Testing and Inspection Page 7552 Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The daytime running lamps system operates the low-beam headlamps at a reduced intensity. The smart junction box (SJB) supplies pulse width modulated (PWM) voltage, 80% of battery voltage, to the low-beam headlamps when the following conditions are met: - the headlamp switch is not in the headlamps ON position - the ignition switch is in the RUN position - the transmission is not in PARK (automatic transmission only) - the parking brake control is released (manual transmission only) Driver Side Page 5342 Rear Subframe: Description and Operation REAR SUBFRAME The rear subframe is bolted to the body and is used to: - aid in structural support. - provide mounting surfaces for the rear suspension control arms. - provide mounting surfaces for the rear differential (4WD). Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts, and drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the doors are often caused by improperly tightened bolts and body misalignment. Page 1046 Page 314 P0480 - P0484: Testing and Inspection P0481 P0481 (Part 1) P0481 (Part 2) Page 2993 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 5091 Adjustment of camber and caster can be made by rotating the upper strut mount into one (1) of four (4) positions. The orientation of the strut rod relative to the center of the hole for the mount determines the alignment change. The strut rod is offset 180 degrees from the paint mark on the strut bushing. Moving the strut rod inboard or outboard changes camber and moving the strut rod forward or rearward changes caster. Regardless of the start setting, a 90 degree rotation will only change one of the settings (caster or camber), and a 180 degree rotation will change both settings (caster and camber). ADDITIONAL FRONT CAMBER ADJUSTMENT: The clearance between the bolts and the holes in the knuckle to strut joint allows front camber adjustment beyond what the strut mount orientation provides. This additional adjustment can be used on either of the front wheels to increase or decrease a camber split. Rotating the upper strut mount is the primary and preferred method to adjust front camber. If rotating the upper strut mount does not provide enough camber adjustment, perform the following steps to achieve an approximate camber change of up to +/- 0.24 degrees per side: 1. Lift the vehicle up off its tires. 2. Replace the old strut to knuckle fasteners (bolts and nuts) with new fasteners, but do not torque the new fasteners. 3. Move the top of the tire inboard or outboard to adjust camber (Figure 4). a. If more negative camber is desired, push the top of the tire inboard. b. If less negative camber is desired, pull the top of the tire outboard. 4. With the tire at the desired position, torque the new fasteners to 85 lb-ft (115 N.m). Page 4885 Locations Page 4101 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 5726 1. Prior to recovery, you must verify the purity of the refrigerant. 2. Connect an R-134a refrigerant center to the low- and high-pressure 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 has been recovered, switch the power supply OFF. 5. Allow the system to set for approximately 2 minutes and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment. 6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes. 7. Carry out the required repairs. Page 7880 Locations View 151-17 (Full Body, Right Rear - 1 Of 2) Page 5705 Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Recover the A/C refrigerant. 3. Remove the 2 compressor manifold and tube assembly bracket nuts. - To install, tighten to 8 Nm (71 lb-in). 4. Disconnect the spring lock coupling from the suction accumulator. 5. Remove the front bumper cover. 6. Disconnect the condenser core peanut fitting. - Remove the condenser core peanut fitting nut. To install, tighten to 8 Nm (71 lb-in). 7. Remove the RH splash shield. 8. If equipped, disconnect the engine block heater. 9. Disconnect the A/C compressor electrical connector. 10. Remove the manifold and tube assembly bolt. - To install, tighten to 20 Nm (15 lb-ft). 11. Remove the A/C compressor manifold and tube assembly. - Remove and discard the O-rings. 12. NOTE: New O-ring seals lubricated with clean mineral oil must be installed before connecting any A/C fitting which has been disconnected. Page 5976 Escape Hybrid vehicles 14. Remove the restraint system diagnostic tool from the vehicle harness side of the passenger air bag module electrical connector. All vehicles 15. Through the glove compartment opening, connect the passenger air bag module electrical connector. 16. Close the glove compartment. 17. Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column. 18. Connect and install the driver air bag module electrical connector. 1 Connect the driver air bag module electrical connector. 2 Through the steering wheel access cover opening, slide the driver air bag module electrical connector onto the pin-type retainer. Page 4199 16. Slide the outer halfshaft boot off the halfshaft. Assembly 1. Lubricate the inner and outer CV joints with joint grease. 2. Install the outer halfshaft boot. 3. Install the snap ring on the halfshaft. 4. Install a new halfshaft bearing retainer circlip. 5. Using a soft-face hammer, install the inner CV joint by gently tapping it onto the halfshaft. 6. Remove any excess grease on the mating surfaces and slide the outer halfshaft joint boot forward onto the outer CV joint. 7. Remove any excess air trapped in the outer halfshaft boot using a cloth-covered screwdriver after adjusting the outer halfshaft boot spacing. 8. Using the special tool, install 2 new outer halfshaft boot clamps. 9. Position the inner halfshaft boot. 10. Install the snap ring. 11. Install the bearing retainer circlip. Page 5228 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 Locations View 151-7 (Engine, front) Page 5920 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 11. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. 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). Page 4905 Speaker Speaker: Diagrams Speaker Page 2412 Valve Clearance: Service and Repair Valve Clearance Check 1. Remove the valve cover. 2. CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in these locations. Left Front View 151-22 (Left Front Door) Page 3197 Oxygen Sensor: Service and Repair Catalyst Monitor Sensor CATALYST MONITOR SENSOR Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the catalyst monitor sensor electrical connector. Page 6103 1. NOTE: Make sure the B-pillar and side impact severity sensor mating surfaces are clean and free of foreign material. Align the side impact sensor locator tabs to the openings in the B-pillar sheet metal. 2. WARNING: The tightening torque of the air bag side impact sensor retaining bolts is critical for correct system operation. Install the side impact sensor bolt. Tighten to 9 Nm (80 lb-in). 3. Connect the side impact sensor electrical connector. 4. Install the B-pillar trim panel. 5. Repower the system. Page 2021 Selector Lever Button Shifter A/T: Service and Repair Selector Lever Button Selector Lever Button Removal 1. Remove the loose selector lever button by carefully prying the button out with a screwdriver. Installation 1. Install a new selector lever button by pressing the button into the selector lever until it clicks into place. Page 6691 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 3393 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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. Locations View 151-15 (Full Body, Left Rear - 1 Of 2) Page 6507 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Description and Operation Sound Proofing / Insulation: Description and Operation INSULATION Insulation is made of urethane, PVC, and recycled felt. The insulation is installed: - under the roof. - above and below the instrument panel. - at the cowl side panels. - over the front and rear floor pans. - inside the A, B, D pillar sections. - behind the rear quarter trim panel. It has heat-bondable mastic deadeners for improved NVH characteristics. Page 4186 7. Using the special tools, remove the front drive halfshaft from the differential. Installation 1. Position the special tool over the halfshaft oil seal. 2. NOTE: When seated correctly, the front drive halfshaft bearing retainer circlip can be felt as it snaps into the differential side gear groove. Position the front drive halfshaft so the splines line up with the differential side gear splines. Push the front drive halfshaft into the differential side gear. 3. Using the special tool, install the front drive halfshaft into the front wheel hub. 4. Position the lower arm into the front wheel knuckle. 5. Install the lower arm pinch bolt and nut. ^ Tighten to 70 Nm (52 ft. lbs.). 6. Install the ABS wheel speed sensor and bolt. ^ Tighten to 9 Nm (80 inch lbs.). 7. Install a new front wheel hub nut. ^ Tighten to 290 Nm (214 ft. lbs.). 8. Check and fill the transaxle fluid as necessary. Intermediate Shaft Intermediate Shaft Page 2199 5. Remove the special tool. 6. Remove the special tool. 7. NOTE: Only turn the engine in the normal direction of rotation. Turn the engine 2 complete revolutions. 8. NOTE: Only turn the engine in the normal direction of rotation. Turn the crankshaft until the No. 1 piston is at TDC. 9. Install the special tool. 10. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Page 3506 14. Route the shortened vent line and spider screen (vent cap) as shown in Figure 1. 15. Push the spider screen (vent cap) at least 2" (50 mm) into the open subframe and body section alignment hole. 16. Secure the vent line to the fuel tank strap with a plastic tie strap. 17. Reposition the filler pipe into its original position. 18. Install the lower filler pipe mounting screw and tighten to 89 lb-in (10 N.m). 19. Install the two (2) upper filler pipe mounting screws and tighten to 27 lb-in (3 N.m). 20. Install the fuel filler cap. 21. Reinstall the wheel and tighten to 98 lb-ft (133 N.m). 22. Lower the vehicle from the hoist. 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 080505A 2005-2008 Escape, 0.7 Hr. Escape Hybrid And Mariner, 2006-2008 Mariner Hybrid: Relocate Fuel Filler Vent Hose. Includes Time to Remove Left Rear Wheel, Fuel Cap And Partially Remove The Fuel Filler Pipe And Shield (Do Not Use With 9030A) DEALER CODING CONDITION BASIC PART NO. CODE 9A089 55 Disclaimer Page 3604 Throttle Position Sensor: Description and Operation Throttle Position (TP) Sensor THROTTLE POSITION (TP) SENSOR The TP sensor monitors the 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 the standards set by government regulations. For additional information on the TP sensor, refer to PCM Inputs. Page 7214 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 5304 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 3217 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor DIFFERENTIAL PRESSURE FEEDBACK EGR (DPFE) SENSOR Differential Pressure Feedback EGR (DPFE) Sensor For information on the DPFE sensor, refer to the description of the Exhaust Gas Recirculation Systems Page 7623 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 3965 Transmission Cooler: Fluid Type Specifications Specifications P1477 P1477 Page 7605 Headlamp Switch: Testing and Inspection Page 5066 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 7257 14. 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. Vehicles with safety canopies NOTE: If the headliner near each B-pillar has the word "AIRBAG" embossed on it, the vehicle is equipped with safety canopy modules. 15. Remove the passenger side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 16. Disconnect the passenger side safety canopy module electrical connector. 1 Slide and disengage the passenger side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the passenger side safety canopy module electrical connector. 17. Attach the restraint system diagnostic tool to the vehicle harness side of the passenger side safety canopy module electrical connector. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair ENGINE OIL CHANGE SOON/ENGINE OIL CHANGE NOW Displayed when the engine oil life remaining is 5% or less. When oil life left is between 5% and 0%, the ENGINE OIL CHANGE SOON message will be displayed. When oil life left reaches 0%, the ENGINE OIL CHANGE NOW message will be displayed. An oil change is required whenever indicated by the message center. USE ONLY RECOMMENDED ENGINE OILS. To reset the oil monitoring system to 100% after each oil change [approximately 5,000 miles (8,000 km) or 12 months] perform the following. 1. Press the SET control to access the system check function. 2. Press and release the SET control to display "OIL CHNG XXX% HOLD SET NEW". 3. Press and hold the SET control for 2 seconds to display "OIL CHANGE SET TO 100%". Page 5336 Rear Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 2551 Exhaust Manifold: Testing and Inspection Exhaust Manifold Cleaning and Inspection 1. Inspect the cylinder head joining flanges of the exhaust manifold for evidence of exhaust gas leaks. 2. Inspect the exhaust manifold for cracks, damaged gasket surfaces, or other damage that would make it unfit for further use. Page 7539 Symbols Part 4 Page 4917 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 4246 Flywheel: Service and Repair Flywheel Removal 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the manual transaxle and clutch. 3. Remove the 6 bolts and the flywheel. Installation 1. NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flywheel and tighten the bolts in the sequence shown in 3 stages. ^ Stage 1: Tighten to 50 Nm (37 ft. lbs.). ^ Stage 2: Tighten to 80 Nm (50 ft. lbs.). ^ Stage 3: Tighten to 112 Nm (83 ft. lbs.). 2. Install the clutch and manual transaxle. Page 2530 Thermostat Housing: Diagrams Thermostat Housing-2.3L NOTE: The thermostat and thermostat housing are serviced as an assembly. P0151 P0151 Page 1716 Page 5312 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 2006 Page 3534 Inertia Fuel Shutoff Switch: Service and Repair INERTIA FUEL SHUTOFF (IFS) SWITCH Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the RH lower A-pillar trim panel. 3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector 4. Remove the 2 bolts and the IFS switch. - To install, tighten to 10 Nm (89 lb-in). 5. To install, reverse the removal procedure. Page 3003 B1-B2 Normal Operation The RCM communicates with the diagnostic tool through the ISO 9141 communication network circuit 70 (LB/WH). If circuit 70 (LB/WH) becomes open or shorted to ground, communication to that module is not possible. Check circuit 70 (LB/WH) between the RCM C2041a and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms there is an open in the ISO 9141 communication network circuit, damage to the DLC C251, or damage to the RCM C2041a. Possible Causes - ISO 9141 communication network circuit 70 (LB/WH) open - DLC C251 - RCM C2041a - RCM Test C: The Anti-Lock Brake System (ABS) Module Does Not Respond to The Diagnostic Tool PINPOINT TEST C: THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL Page 4994 Service and Repair Ignition Switch Lock Cylinder: Service and Repair IGNITION LOCK CYLINDER Removal and Installation 1. Disconnect the battery. 2. Turn the ignition key to the ON position. 3. Using a small tool, press the ignition lock cylinder release button and pull the ignition lock cylinder out. 4. To install, reverse the removal procedure. Page 1576 2. 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. - Failure to route the seat occupant classification sensor components through the correct seat cushion support opening can cause component failure. - 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. Feed the OCS components (pressure sensor and hose) through the seat cushion pan opening. 3. Align the OCS bladder to the seat cushion pan. 4. Install the 2 pin-type retainers to the OCS bladder and seat cushion pan. 5. NOTE: Make sure the pressure sensor hose is not kinked during installation. Install the pressure sensor onto the seat cushion pan bracket, making sure the retaining tab is completely engaged. When installed correctly, an audible click will be heard and the pressure sensor will not be able to be removed from its bracket without disengaging the retaining tab. 6. Slide the OCS ECU into the seat cushion pan bracket and install the rivets. - The OCS 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). 7. Position the foam pad to the seat cushion pan. 8. 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. Install seat cushion trim cover to seat cushion foam pad and attach the J-clips. 9. 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. Position the seat cushion and pan assembly to the seat track. To aid in installation, recline the seat. 10. Install the 4 seat cushion bolts retaining the seat cushion to the seat track. - Tighten to 15 Nm (11 lb-ft). Page 7638 Symptom Chart Page 6757 Rear Subframe: By Symptom Technical Service Bulletin # 10-22-8 Date: 101122 Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 4210 3. NOTE: This step may not be necessary if the inner wheel bearing race remains in the wheel knuckle after removing the wheel hub. Using the special tool, press the inner wheel bearing race from the wheel hub. 4. Remove the snap ring. 5. Using the special tools, press the outer wheel bearing race from the wheel knuckle. Installation 1. Position the wheel knuckle in a vise. 2. NOTE: Special Tool 205-278 is not seen in place. It is located behind the wheel knuckle. Using the special tools, install the wheel bearing into the wheel knuckle. 3. Install the snap ring. 4. Using the special tool, press the wheel hub into the wheel bearing. 5. Install the wheel knuckle. Page 5405 7. NOTE: Reference mark the 4 strut upper bushing plate nuts. Remove the 4 strut upper bushing nuts. 8. CAUTION: Do not allow the axle shaft to move outboard. Over-extension of the tripod CV joint can result in the separation of internal parts, causing failure of the axle shaft. Remove the strut and spring assembly. Installation 1. Position the strut and spring assembly upper mounting plate into the inner fender. 2. Align the 4 strut upper bushing nuts to the reference marks. ^ Tighten to 40 Nm (30 ft. lbs.). 3. Install the 2 strut-to-knuckle bolts and nuts. ^ Tighten to 115 Nm (85 ft. lbs.). 4. Install the upper stabilizer bar link nut. ^ Tighten to 63 Nm (46 ft. lbs.). 5. Install the ABS wheel speed sensor harness bolt. ^ Tighten to 23 Nm (17 ft. lbs.). 6. Position the brake jounce hose to the bracket and install the brake jounce hose clip. 7. Check the front end alignment and adjust as necessary. Page 5163 2. Disconnect the power steering pressure switch electrical connector 3. NOTE: Drain the power steering fluid into a suitable drain pan. Disconnect the power steering pressure line fitting nut from the power steering pump. 4. Remove the 2 lower power steering pump bolts. 5. Remove the power steering pressure line bracket nut and position the pressure line aside. 6. Release the clamp and disconnect the suction hose from the power steering pump. 7. Remove the 2 upper power steering pump bolts and remove the power steering pump. 8. If necessary, using the special tool, remove the steering pump pulley. Installation 1. CAUTION: Install a new power steering pump pulley after the second removal and installation. SRS - Passenger Air Bag Lamp ON/DTC C1414 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Passenger Air Bag Lamp ON/DTC C1414 Set TSB 05-15-14 08/08/05 PASSENGER AIR BAG DISABLED (PAD) LAMP INTERMITTENTLY ON WHILE DRIVING - DTC C1414 RETRIEVED DURING OCS DIAGNOSIS/REPAIR FORD: 2005 Escape Hybrid, Escape MERCURY: 2005 Mariner ISSUE Some 2005 Escape/Escape Hybrid and Mariner vehicles may exhibit the passenger air bag disabled (PAD) lamp intermittently on while driving with the passenger seat occupied, or diagnostic trouble code (DTC) C1414. ACTION Revised occupant classification system (OCS) Service Kits are available for vehicles built at Kansas City Assembly Plant from Job 1 to 2/2/2005, and for vehicles built at Ohio Assembly Plant from Job 1 to 2/8/2005. Install a revised OCS Service Kit to correct the intermittent PAD lamp. It is necessary to re-zero the OCS system after components are replaced. Refer to Workshop Manual Section 501-20B for this procedure. For DTC C1414, ensure the correct components are installed. Refer to the Service Procedure for descriptions of PAD lamp operation and DTC C1414 origination. Refer to the TSB charts for Service Kit selection and/or correct component verification. SERVICE PROCEDURE NOTE THE 11TH DIGIT OF THE VIN CAN BE USED TO IDENTIFY THE ASSEMBLY PLANT (KANSAS CITY = K, OHIO = D). NOTE Page 4287 6. Engage the secondary shift cable lock by sliding it over the primary shift cable lock. 7. Install the floor console. Specifications Wheel Fastener: Specifications 5 Wheel nuts. Tighten the wheel nuts in a star pattern. Tighten to ............................................................................ .............................................................................................................. 133 Nm (98 ft. lbs.) Page 346 P0553 Deactivator Switch Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Engine Control Module: Service and Repair Flash Electrically Erasable Programmable Read Only Memory (EEPROM) FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) Description The flash electrically erasable 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 programmed or flashed repeatedly. As part of the calibration there is an area referred to as the vehicle identification (VID) block. The VID block is programmed when installing a new PCM as described under Programming the VID Block for a Replacement PCM. Failure to carry out this procedure may generate fault code P1635 or P1639. The VID block in an existing PCM can also be tailored to accommodate various hardware or parameter changes made to the vehicle since production. Failure to carry out this procedure properly may generate fault code P1635, Tire/Axle Ratio out of Acceptable Range. An incorrect tire/axle ratio is one of the main causes for fault 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, 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 (ESOF) versus manual shift-on-the-fly (MSOF). Only items applicable to the vehicle hardware and supported by the VID block will display on the diagnostic tool. When changing items in the VID block, the strategy places range limits on certain items such as tire and axle ratio. The number of times the VID block may be reconfigured is limited. When this limit is reached, the diagnostic tool displays 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). Programming can be carried out by a local Ford dealer or any non-Ford facility. There are other enhanced diagnostic tools that may have programming capabilities available. Refer to the manufacturer's user manual for details. Programming the VID Block for a Replacement PCM A new PCM contains the latest strategy and calibration level for a particular vehicle. However, the VID block is blank and 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 is carried out if the old PCM is capable of communicating. This is done by the use of a diagnostic 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 installed. Manual data entry must be Carried out if the old module is damaged or incapable of communicating. Remove and install a new PCM. Using a compatible diagnostic tool, select and carry out the Module/Parameter programming, referring to the manufacturer's user manual. Make certain that all parameters are included. Failure to properly program tire size in revolutions per mile, (rev/mile = 83,360 divided by the tire circumference in inches), axle ratio, 4x4/4x2, and/or MSOF/ESOF may result in codes P1635 and P1639. You may be instructed to contact the As-Built Data Center for the information needed to manually update the VID block with the diagnostic tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford and L-M technicians, contact your National Hotline or the Professional Technician Society (PTS) web site for As-Built data. Non-Ford technicians use the Motorcraft website at www.motorcraft.com. From the Motorcraft homepage, use the search function to find the Module Programming or As Built Data. For Ford and L-M technicians, check the Programmable Module Installation link on the PTS website for quick Programmable Module data information by vehicle when using the WDS or New Generation Star (NGS). Making Changes to the VID Block A PCM which is programmed may require changes to be made to certain VID information to accommodate the vehicle hardware. Refer to PCM/Module Reprogramming on the diagnostic tool. Making Changes to the PCM Calibration At certain times, the entire EEPROM needs to be completely reprogrammed. This is due to changes made to the strategy or calibration after production, or the need to reset the VID block because it has reached its limit. Refer to PCM/Module Reprogramming on the diagnostic tool. Page 2013 Page 5566 7. Using the special tool, install the A/C clutch bolt. - Tighten to 13 Nm (10 lb-ft). 8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install the A/C compressor. Page 2360 4. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump. Position the power steering pump and install the bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 5. Install the 2 remaining power steering pump bolts. ^ Tighten to 25 Nm (18 ft. lbs.). 6. Install the coolant pump pulley and bolts. ^ Tighten to 20 Nm (15 ft. lbs.). 7. NOTE: Remove the through-bolt from the special tool. NOTE: Lubricate the oil seal with clean engine oil. Using the special tool, install the crankshaft front oil seal. 8. NOTE: Do not reuse the crankshaft pulley bolt. NOTE: Apply clean engine oil on the seal area before installing. Install the crankshaft pulley and hand-tighten the bolt. Page 2822 Knock Sensor: Service and Repair KNOCK SENSOR (KS) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Remove the intake manifold. 4. Remove the bolt and the knock sensor. - To install, tighten to 20 Nm (15 lb-ft). 5. To install, reverse the removal procedure. Page 6690 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 1206 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 6541 Escape Is Shown, Mariner Is Similar (Part 2) Exploded Views Special Tool(S) Special Tool(s) Removal and Installation 1. Remove the rear bumper cover. 2. Remove the 4 rear bumper nuts. - To install, tighten to 25 Nm (18 lb-ft). 3. Remove the rear bumper. 4. If necessary, remove the rivets and the rear bumper isolator. - Use the special tool to install the new rivets. 5. To install, reverse the removal procedure. Page 7671 License Plate Lamp: Connector Views Locations View 151-25 (Liftgate) Mechanical Specifications Page 3571 Air Flow Meter/Sensor: Description and Operation MASS AIR FLOW (MAF) SENSOR Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot And Cold Wire Terminals Typical Mass Air Flow (MAF) Sensor Locations Page 7181 Clutch Switch: Description and Operation CLUTCH PEDAL POSITION (CPP) SWITCH Typical Clutch Pedal Position (CPP) Switch The CPP switch is an input to the PCM indicating the clutch pedal position. The PCM provides a low current voltage on the CPP circuit. When the CPP switch is closed, this voltage is pulled low through the SIG RTN circuit. The CPP input to the PCM is used to detect a reduction in engine load. The PCM uses the load information for mass air flow and fuel calculations. 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 Parking Assist System - Speaker Inop./DTC C1742/C1743 Parking Assist Control Module: All Technical Service Bulletins Parking Assist System - Speaker Inop./DTC C1742/C1743 TSB 06-20-5 10/16/06 PARKING AID SPEAKER INOPERATIVE - DTCS C1742 AND C1743 FORD: 2005-2007 Five Hundred, Freestyle 2004-2006 Escape, Expedition, Explorer, F-150 2004-2007 F-250, F-350 MERCURY: 2005-2007 Montego 2004-2006 Mountaineer 2005-2006 Mariner ISSUE Some 2004-2007 vehicles equipped with the parking aid reverse sensing system (RSS) may experience low or no audible sound due to speaker issues related to the RSS. The speaker is attached to the module which may exhibit diagnostic trouble codes (DTCs) C1742 (Rear Sounder Circuit Fault) and/or C1743 (Rear Sounder Short). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Verify that DTCs C1742 and/or C1743 are present. Also, low audible or intermittent audible warning condition may exist as well. 2. If DTCs C1742 and/or C1743 are present, replace parking aid speaker on module with speaker in Speaker Kit. Follow instructions in Speaker Kit. 3. Clear DTCs and repeat check for DTCs C1742 and/or C1743. 4. If DTCs C1742 and/or C1743 go away and speaker sounds, the repair is complete. 5. If DTCs remain, follow normal diagnostics in the appropriate Workshop Manual, Section 413-13 Pinpoint Test F. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 062005A 2004-2006 Expedition: 1.2 Hrs. Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) 062005A 2004-2007 Super Duty 0.6 Hr. 250/350: Replace Parking Aid Speaker, Includes Time To Access Module (Do Not Use With 31012AR, 31012AL, 31012AT) P1265 P1265 Dual Converter Y-Pipe Exhaust Pipe: Service and Repair Dual Converter Y-Pipe Dual Converter Y-Pipe Special Tool(s) Material Page 3642 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the camshaft position sensor (CMP) sensor electrical connector. 3. Remove the bolt and the CMP. - To install, tighten to 7 Nm (62 lb-in). - Inspect the O-ring seal and install new as necessary. 4. NOTE: Lubricate the CMP O-ring seal with clean engine oil. To install, reverse the removal procedure. P0270 P0270 Page 7629 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 7168 View 151-14 (Under Dash Panel, LH Side) Page 6476 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 1294 Service and Repair Oil Cooler: Service and Repair Oil Cooler Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Remove the oil drain plug and drain the engine oil. ^ To install, tighten to 28 Nm (21 ft. lbs.). 4. Remove and discard the oil filter. ^ To install, tighten 3⁄4 of a turn after the filter gasket makes contact with the oil filter adapter. 5. Drain the engine cooling system. 6. Disconnect the 2 coolant hoses from the oil cooler. 7. Disconnect the oil pressure sender electrical connector. 8. NOTE: Discard the gasket. Remove the 4 bolts and the oil filter adapter. ^ To install, tighten to 25 Nm (18 ft. lbs.). 9. CAUTION: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Page 6407 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 2821 Knock Sensor: Description and Operation KNOCK SENSOR (KS) Two Types Of Knock Sensor (KS) The KS is a tuned accelerometer on the engine which converts engine vibration to an electrical signal. The PCM uses this signal to determine the presence of engine knock and to retard spark timing. Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the heated oxygen sensor (HO2S) electrical connector. Page 4827 Fuse Block: Application and ID Battery Junction Box Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Left Front Page 4484 Transmission Speed Sensor: Service and Repair Output Shaft Speed (OSS) Sensor Output Shaft Speed (OSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the Output Shaft Speed (OSS) sensor. 1 Disconnect the OSS electrical connector. 2 Remove the OSS sensor bolt. 3 Remove the OSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 560 P1288 Page 6930 Power Mirror Switch: Service and Repair EXTERIOR MIRROR CONTROL SWITCH Removal and Installation 1. Remove the exterior mirror control switch. - Disconnect the electrical connector. 2. To install, reverse the removal procedure. Page 5366 (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Page 93 P0148 Page 7821 B1342-B2070 Page 1578 - The ignition switch must be cycled after rezeroing the OCS system. Rezero the occupant classification sensor. With the front passenger seat empty, use a diagnostic tool to trigger the active command and rezero the occupant classification sensor. 15. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 5561 Compressor Clutch: Adjustments AIR CONDITIONING (A/C) CLUTCH AIR GAP ADJUSTMENT 1. Check the A/C clutch air gap at 3 equally spaced places between the clutch plate and the A/C clutch pulley. 2. If the A/C clutch air gap is out of range, remove the clutch plate. Add or remove spacers between the clutch plate hub and the compressor shaft until the clearance is within specification. Page 2765 Typical Drop-in Mass Air Flow (MAF) Sensor The MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at 200°C (392°F) above the ambient temperature as measured by a constant cold wire. 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 mass air flow. The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air mass. The PCM calculates the required fuel injector pulse width in order to provide the desired air/fuel ratio. This input is also used in determining transmission electronic pressure control (EPC), shift and torque converter clutch scheduling. 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 5619 Coupler HVAC: Service and Repair Air Conditioning Line (Peanut) Fitting AIR CONDITIONING LINE (PEANUT) FITTING Disconnect 1. Remove the nut and separate the 2 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 new, green, O-ring seals. The use of any O-ring seals other than those specified 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. System Diagnosis P0360 Connector Views Fuse Block: Connector Views Page 7789 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 2864 Valve Clearance: Service and Repair Valve Clearance Check 1. Remove the valve cover. 2. CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt. NOTE: Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. Use a feeler gauge to measure the clearance of each valve and record its location. 3. NOTE: The number on the valve tappet only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm. NOTE: A midrange clearance is the most desirable: ^ Intake: 0.22-0.28 mm (0.008-0.011 inch) ^ Exhaust: 0.27-0.33 mm (0.010-0.013 inch) Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness. Select the tappets and mark the installation location. 4. If any tappets do not measure within specifications, install new tappets in these locations. Page 6140 11. Connect the electrical connectors and wiring clips. 1 Connect the OCS ECU electrical connector. 2 Connect the pressure sensor electrical connector. 3 Install the 2 wiring clips on the wiring harness to the cushion pan. 4 If equipped with heated seats, connect the heated seat module electrical connector, install the wiring clip on the wiring harness to the cushion pan, and connect the 2 cushion element electrical connectors. 12. Install the passenger seat into the vehicle. 13. Repower the system. Do not prove out the system at this time. 14. CAUTION: - 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 an NGS+ (NGS with Vehicle Communication Module (VCM) and the latest software update) to rezero the OCS system: select "FUNCTION TEST" - select "SYSTEM RESET" - 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 display "TEST/FUNCTION SUCCESSFUL" 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. - If the first attempt to rezero the OCS system is unsuccessful, a second attempt must be made. Page 4708 View 151-17 (Full Body, Right Rear - 1 Of 2) Page 159 P0223 Page 7210 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 5644 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 7948 6. Apply glass primer to the same area that was prepped in the previous step. Allow 5 minutes to dry. 7. Cut the urethane adhesive applicator tip to specification. 8. NOTE: - Use caution when applying urethane adhesive. Apply to the outside edges of locating pins on the glass surface. - Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. Apply a bead of urethane adhesive starting at the bottom and work around to the sides of the rear quarter window glass. 9. Install the rear quarter window glass, aligning it to the marks previously made. 10. NOTE: The urethane adhesive must cure for a minimum of 1 hour before testing for air or water leaks. After the urethane has cured, check for water leaks and add urethane adhesive where needed. 11. If necessary, remove excess urethane adhesive from the exterior surface of the quarter window glass. 12. Install the headliner. LH Quarter Window Glass 13. If equipped, install the auxiliary climate control upper housing bracket and the bolt. 14. If equipped, install the auxiliary climate control housing. Page 1474 Fuel Pressure Sensor/Switch: Service and Repair FUEL RAIL PRESSURE AND TEMPERATURE SENSOR Removal and Installation 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 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 tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury. 1. Release the fuel system pressure. 2. Disconnect the battery ground cable. 3. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube. 4. Remove the 2 bolts and the fuel rail pressure and temperature sensor. - To install, tighten to 5 Nm (44 lb-in). - Inspect the O-ring seal and install new as necessary. 5. NOTE: Lubricate the fuel rail pressure and temperature sensor O-ring seal with clean engine oil. To install, reverse the removal procedure. Page 1404 Description and Operation EGR Tube: Description and Operation ORIFICE TUBE ASSEMBLY Orifice Tube Assembly The orifice tube assembly is a section of tubing connecting the exhaust system to the intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also contains the metering orifice and 2 pressure pick-up tubes. The internal metering orifice creates a measurable pressure drop across it as the EGR valve opens and closes. This pressure differential across the orifice is picked up by the DPFE sensor which provides feedback to the PCM. P1100 P1100 Transmission Range (TR) Sensor Occupant Classification Sensor - Original Equipment Seat Occupant Sensor: Service and Repair Occupant Classification Sensor - Original Equipment OCCUPANT CLASSIFICATION SENSOR - ORIGINAL EQUIPMENT Worldwide Diagnostic System (WDS) Special Tool(s) Locations View 151-8 (Engine, rear) Page 7067 Specifications Compression Check: Specifications Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Page 2979 Symbols Part 2 Page 7461 K7-K8 Normal Operation When the brake pedal is applied, the stoplamp switch allows voltage to flow through circuit 511 (LG). Circuit 511 (LG) provides voltage to the high mounted stoplamp and the smart junction box (SJB). The SJB then provides voltage to the LH and RH rear lamps through circuits 22 (LB/BK) and 810 (RD/LG), respectively. All the stoplamp are provided ground through circuit 57 (BK). Possible Causes - circuit 22 (LB/BK) open or short to ground - circuit 57 (BK) open - circuit 511 (LG) open - circuit 810 (RD/LG) open or short to ground - high mounted stoplamp - SJB Test L: The Stoplamps Are On Continuously PINPOINT TEST L: THE STOPLAMPS ARE ON CONTINUOUSLY L1 Steering Gear Steering Gear: Service and Repair Steering Gear Steering Gear Special Tool(s) Page 3881 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 7998 Windshield Washer Pump: Service and Repair Windshield Washer Pump WINDSHIELD WASHER PUMP Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the RH front fender splash shield. 3. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: When replacing the windshield washer pump, be careful not to damage the rubber grommet. NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before washer pump removal. Remove the windshield washer pump. 1 Disconnect the electrical connector. 2 Disconnect the hose. 3 Remove the windshield washer pump. 4. WARNING: Windshield washer solution contains methanol, which is poisonous. Observe all cautions and warnings indicated on the label of the washer solution container. Failure to follow these instructions may result in personal injury. CAUTION: Do not operate the windshield washer pump prior to filling the windshield washer reservoir. Failure to follow these instructions may result in premature pump failure. To install, reverse the removal procedure. Fill the windshield washer reservoir with windshield washer fluid. Page 4879 Locations Number One Cylinder: Locations Firing Order ......................................................................................................................................... ...................................................................... 1-3-4-2 Page 5311 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 5971 18. Remove the driver side D-pillar trim panel. 1 Separate the weatherstrip. 2 Pull out and separate the quarter trim panel at the D-pillar trim panel. 3 Pull out to release the retainers and remove the D-pillar trim panel. 19. Disconnect the driver side safety canopy module electrical connector. 1 Slide and disengage the driver side safety canopy module electrical connector locking clip. 2 Push in to release the tab and disconnect the driver side safety canopy module electrical connector. 20. Attach the restraint system diagnostic tool to the vehicle harness side of the driver side safety canopy module electrical connector. Escape Hybrid, Mariner and late build Escape vehicles without side air bags 21. CAUTION: Do not deactivate the side air bag module circuit by removing the side air bag bridge resistor from the side air bag 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. Escape Hybrid, Mariner and late build Escape vehicles with side air bags Page 6433 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 1979 Page 1911 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Type ..................................................................................................................................................... ............. SAE 80W-90 Premium Rear Axle Lubricant Page 4090 Symbols Part 3 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 7818 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 4124 3. Gently pry up to remove the upper shift lever trim ring. 4. Remove the top finish panel. 5. Disconnect the overdrive cancel switch electrical connector. 6. Remove the set screw. Page 6926 Locations Page 5836 Table lists each of the fault PIDs as displayed on IDS/PDS and their description. (Figures 1-5) WARRANTY STATUS: Information Only Disclaimer Page 1618 Power Steering Pressure Switch: Description and Operation Power Steering Pressure (PSP) Sensor POWER STEERING PRESSURE (PSP) SENSOR Typical Power Steering Pressure (PSP) Sensor The PSP sensor monitors the hydraulic pressure within the power steering system. The PSP sensor voltage input to the PCM 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 the transmission electronic pressure control (EPC) pressure during increased engine load, for example during parking maneuvers. Page 6226 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 5053 Relay Box: Application and ID Battery Junction Box Page 7860 Page 7314 Fuel Gauge Sender: Description and Operation Fuel Pump Module FUEL PUMP MODULE Fuel Pump Module (For Returnable Fuel Systems) Page 7672 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 Forward Crash Sensor Page 7813 Splice tape removed 1 Intermittent short Splice covered 1 Wire strand 2 Splice tape 3 Harness tape Page 2353 Timing Cover: Service and Repair Engine Front Cover Special Tool(s) Material Page 2312 6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 25 Nm (18 ft. lbs.). 7. Install the flexplate or flywheel. Page 1039 Page 3172 Driver Side View 151-20 (Driver Seat) Page 7604 Fuel Pump Module and Reservoir Fuel Gauge Sender: Description and Operation Fuel Pump Module and Reservoir FUEL PUMP MODULE AND RESERVOIR Fuel Pump Module And Reservoir The fuel pump module is mounted inside the fuel tank in a reservoir. The pump has a discharge check valve that maintains the system pressure after the ignition key has been turned off to minimize starting concerns. The reservoir prevents fuel flow interruptions during extreme vehicle maneuvers with low tank fill levels. Page 3138 3. Remove the plug. 4. Turn the crankshaft pulley bolt to position the number one cylinder at top dead center and install the special tool. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the bolts and the CKP sensor. Installation 1. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur. Install a 6-mm (0.23-in) x 18-mm (0.7-in) standard bolt in the crankshaft pulley. 2. Install the CKP sensor and the bolts. - Do not tighten the bolts at this time. 3. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately. Adjust the CKP sensor with the alignment jig. Tighten the CKP bolts to 7 Nm (62 lb-in). 4. Remove the 6-mm (0.23-in) bolt from the crankshaft pulley. 5. Install the plug. - Tighten to 10 Nm (89 lb-in). 6. Connect the battery ground cable. Specifications Fuel: Specifications Fuel Type ............................................................................................................................................. ................................................ Unleaded 87 Octane Page 7332 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 6 seconds and then turn off. If an SRS fault is present, the air bag indicator will: - fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the 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 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be repaired before diagnosis can continue. Page 2134 2. If compression does not improve, valves are sticking or not seating correctly. 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 254 P0359 Locations View 151-13 (Behind Dash Panel) Fuel Tank Pressure Transducer Sensor View 151-15 (Full Body, Left Rear - 1 Of 2) Page 480 P1131 Interior - Headliner Sagging Near Rear Hatch Headliner: All Technical Service Bulletins Interior - Headliner Sagging Near Rear Hatch TSB 05-8-3 05/02/05 HEADLINER SAGGING NEAR REAR HATCH FORD: 2004-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2004-2005 vehicles may exhibit the headliner sagging around the rear hatch perimeter edge. ACTION Adhere the headliner to the underside of the roof panel. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Remove the perimeter seal near the sagging edge (Figure 1). 2. Without removing the headliner push pins, pull the headliner down far enough to scuff/sand the back side of the headliner and the underside of the roof panel. 3. Prepare the cartridge of Motorcraft Plastic Bonding Adhesive (TA-9), and apply the adhesive to the back side of the headliner (Figure 2). Page 1853 Removal and Installation CAUTION: While 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. NOTE: New O-rings must be installed any time the lines are disconnected from the steering gear. 1. Drain the power steering fluid into a suitable drain pan. 2. Release the clamp and disconnect the steering gear-to-fluid cooler return hose from the power steering cooler. 3. Remove the steering gear-to-fluid cooler return hose bracket-to-steering gear stud. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. Remove the steering gear-to-fluid cooler return hose bracket-to-subframe bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Remove the power steering line clamp plate bolt. ^ To install, tighten to 25 Nm (18 inch lbs.). 6. NOTE: The power steering pressure and return lines are of different diameters and the O-rings are not interchangeable. Rotate the clamp plate and remove the steering gear-to-fluid cooler return hose. ^ Install a new return hose O-ring seal. 7. To install, reverse the removal procedure. ^ Fill the power steering system. Pressure, Vacuum and Temperature Specifications Engine Oil Pressure: Pressure, Vacuum and Temperature Specifications Oil pressure (hot @ 2,000 rpm) ...................................................................................................................................................... 29-39 psi (200-268 kPa) Body/Frame - Front/Rear Squeak/Creak Noises Rear Subframe Mount: All Technical Service Bulletins Body/Frame - Front/Rear Squeak/Creak Noises TSB 10-22-8 11/22/10 FRONT AND/OR REAR CREAK/SQUEAK NOISE DUE TO SUBFRAME LOCATING PINS CONTACTING VEHICLE BODY FORD: 2001-2011 Escape MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. Page 4990 Page 4274 3. Connect the gearshift cable. 4. Install the 2 gearshift cable grommet nuts. ^ Tighten to 10 Nm (89 inch lbs.). 5. CAUTION: Make sure the clips are set completely within the cable adapter groove and fully seated. Install the 2 gearshift cable clips. 6. Connect the gearshift cables to the transaxle gearshift control assembly. 7. Adjust the gearshift cables. 8. Install the floor console. Diagrams Page 7732 Backup Lamp Switch: Service and Repair REVERSING LAMP SWITCH Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Page 1507 Crankshaft Position Sensor: Diagrams Page 1073 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 5840 Page 5265 Stabilizer Link: Service and Repair Stabilizer Bar Link Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. NOTE: Use the hex holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. Remove the upper stabilizer bar link nut. ^ To install, tighten to 63 Nm (46 ft. lbs.). 3. NOTE: Use the hex holding feature to prevent the ball stud from turning while removing or installing the stabilizer link nut. Remove the lower stabilizer bar link nut. ^ To install, tighten to 55 Nm (41 ft. lbs.). 4. NOTE: Inspect the stabilizer bar link ball joints and boots for wear. If necessary, install new parts. Remove the stabilizer bar link. 5. To install, reverse the removal procedure. Liftgate Handle, Lock and Latch - Exploded View Trunk / Liftgate Latch: Service and Repair Liftgate Handle, Lock and Latch - Exploded View LIFTGATE HANDLE, LOCK AND LATCH - EXPLODED VIEW Removal and Installation System Diagnosis P1474 Page 1508 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSOR Three Different Types Of Crankshaft Position (CKP) Sensors The 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 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 10-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 PCM uses the CKP signal to synchronize the ignition system and track the rotation of the crankshaft. Page 5314 (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the front subframe front nuts. Refer to WSM, Section 502-00. NOTE WHEN INSTALLING THE FRONT SUBFRAME REAR BOLTS, ENSURE BOTH FRONT SUBFRAME REAR BOLTS ARE FULLY ENGAGED IN THEIR CAGE NUTS BEFORE TIGHTENING TO SPECIFICATION. (4) Tighten the front subframe rear attachment bolts. Refer to WSM Section 502-00. (5) Adjust front caster, camber, and toe. Refer to WSM, Section 204-00. 2001-2011 - Rear - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 3) a. No - Do not continue with this procedure. Proceed to WSM, Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the four (4) rear subframe bolts. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 4) NOTE NOTE: THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. (3) Tighten the four (4) subframe bolts. Refer to WSM, Section 502-00. (4) Adjust rear toe. Refer to WSM, Section 204-00. 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 102208A 2001-2011 Escape, 0.6 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Diagnose Using Chassis Ears, And Road Test. Can Page 1432 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 5541 Blower Motor Relay: Testing and Inspection Page 301 P0455 - P0459: Testing and Inspection P0456 P0456 (Part 1) P0456 (Part 2) Paint Codes Paint: Application and ID Paint Codes PAINT CODES Vehicle Certification Label The VC label is located on the left-hand door jamb. Exterior Paint Code Page 6617 - Disconnect the electrical connector. 5. To install, reverse the removal procedure. Page 5107 2. NOTE: Do not remove the rear knuckle cam nut and wheel knuckle bolts. If removed, clean the serrations in the bushing sleeve with a wire brush and install a new wheel knuckle bolt and cam nut. Loosen the LH and RH rear wheel knuckle bolts. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear wheel knuckle bolts. ^ Using a suitable tool, hold the adjustment cam nut stationary while tightening the rear wheel knuckle bolt. ^ Tighten to 115 Nm (85 ft. lbs.). Locations View 151-7 (Engine, front) 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 6132 System Diagnosis P0175 Description and Operation Oil Temperature Sensor/Switch: Description and Operation ENGINE OIL TEMPERATURE (EOT) SENSOR Typical Engine Oil Temperature (EOT) Sensor The EOT sensor is a thermistor device in which resistance changes with temperature. The electrical resistance of a thermistor decreases as the temperature increases and the resistance increases as the temperature decreases. The varying resistance 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. 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. General Procedures Windshield: Service and Repair General Procedures WINDSHIELD RESEAL 1. Remove the 4 covers, the 4 bolts and the 2 A-pillar passenger assist handles. 2. Remove the 2 windshield side garnish mouldings. 3. Open the front overhead console door, remove the 2 screws and the overhead console. - If equipped, disconnect the electrical connector. 4. Remove the 6 screws, 2 sun visors and 2 clips. 5. Partially lower the front portion of the headliner and block with a suitable material. 6. Remove the cowl panel grille. 7. Clean the interior and exterior of the windshield glass surface with non-alcohol based glass cleaner. 8. Cut the urethane adhesive applicator tip to specification. 9. NOTE: - Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane with less effort and a continuous bead. - Make sure all gaps in the urethane adhesive are smoothed into one continuous bead. Apply urethane adhesive over the top of the existing urethane adhesive. Apply the urethane adhesive to the top and sides of the windshield from the interior of the vehicle. - Apply the urethane adhesive to the bottom of the windshield from the exterior of the vehicle. 10. NOTE: The urethane adhesive must cure for a minimum of 1 hour before testing for air or water leaks. After the urethane has cured, check the windshield seal for air or water leaks through the urethane adhesive bead and add urethane adhesive as necessary. 11. Install the cowl panel grille. 12. Position the front portion of the headliner. 13. Position the 2 sun visors, 2 clips and install the 6 six screws. 14. Position the overhead console and install the 2 overhead console screws. - If equipped, connect the electrical connector. 15. Install the 2 windshield side garnish mouldings. 16. Position the 2 A-pillar passenger assist handles, and install the 4 bolts and the 4 covers. - Tighten to 5 Nm (44 lb-in). Service and Repair Power Mirror Motor: Service and Repair EXTERIOR MIRROR MOTOR Removal and Installation 1. Remove the exterior mirror glass. 2. Remove the 3 exterior mirror motor screws. 3. Disconnect the electrical connector and remove the exterior mirror motor. 4. To install, reverse the removal procedure. Page 7928 Power Window Switch: Service and Repair WINDOW CONTROL SWITCH Removal and Installation NOTE: - The LH front window control switch is shown, all others are similar. - The removal and installation procedures for all window control switches are similar. 1. Remove the front door trim panel or the rear door trim panel. 2. Release the window control switch bezel from the door trim panel. 3. Release the locking tabs and remove the window control switch from the bezel. 4. To install, reverse the removal procedure. Page 1461 Air Flow Meter/Sensor: Diagrams Air Bag Disarming and Arming Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming SUPPLEMENTAL RESTRAINT SYSTEM (SRS) DEACTIVATION AND REACTIVATION 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. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. NOTE: - If a seat equipped with a supplemental restraint system (SRS) component is being serviced, the SRS must be depowered. - After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road. - The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - The SRS must be fully operational and free of faults before releasing the vehicle to the customer. - Seat side air bag modules or seat side air bag bridge resistors are available on Escape Hybrid, Mariner and late build Escape vehicles only. All vehicles 1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the smart junction box (SJB), located at the RH side of the center console, remove the cover and the restraints control module (RCM) fuse F33 (15A) from the CJB. 4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air bag indicator will remain lit continuously (no flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit continuously, remove the correct RCM fuse before proceeding. 5. Turn the ignition OFF. Page 1496 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR Removal and Installation 1. Disconnect the battery ground cable. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 screws and the TP sensor. - To install, tighten to 10 Nm (89 lb-in). 4. To install, reverse the removal procedure. Page 1573 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. - To reduce the risk of personal injury, do not use any memory saver devices. - Do not separate components. CAUTION: - There are 2 occupant classification sensor (OCS) system service kits available for this vehicle (base seat and heated 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, or an OCS service kit is installed. A diagnostic 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 (ECU), 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 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 2096 Special Tool(s) Removal NOTE: If removing the wheel hub, the wheel bearing must be replaced. 1. Remove the wheel knuckle. 2. Using the special tool, press the wheel hub from the wheel bearing. Page 6648 3. Through the RH access, disconnect the liftgate window glass electrical harness connector. 4. Disconnect the LH heated window grid wire electrical connector. 5. NOTE: An assistant may be needed to carry out this step. Disconnect the 2 liftgate window glass cylinders. 1 Slide the spring retainer to the end of the socket. 2 Disconnect the socket from the ball stud. 6. NOTE: An assistant may be needed to carry out this step. Remove the 2 liftgate window glass hinge nuts and the liftgate window glass. To install, tighten to 7 Nm (62 lb-in). 7. To install, reverse the removal procedure. - Transfer components as necessary. Fuel Rail Pressure Temperature (FRPT) Sensor Fuel Temperature Sensor: Description and Operation Fuel Rail Pressure Temperature (FRPT) Sensor FUEL RAIL PRESSURE TEMPERATURE (FRPT) SENSOR Fuel Rail Pressure Temperature (FRPT) Sensor The FRPT sensor measures the pressure and temperature of the fuel in the fuel rail and sends these signals to the PCM. The sensor uses the intake manifold vacuum as a reference to determine the pressure difference between the fuel rail and the intake manifold. The fuel return line to the fuel tank has been deleted in this type of fuel system. The relationship between fuel pressure and fuel temperature is used to determine the possible presence of fuel vapor in the fuel rail. Both pressure and temperature signals are used to control the speed of the fuel pump. The speed of the fuel pump sustains fuel rail pressure which preserves fuel in its liquid state. The dynamic range of the fuel injectors increase because of the higher rail pressure, which allows the injector pulse width to decrease. Page 6377 Parking Assist Control Module: Service and Repair PARKING AID MODULE Removal and Installation 1. Remove the RH rear quarter trim panel. 2. Disconnect the electrical connectors. 3. Remove the 2 screws and the parking aid module. 4. To install, reverse the removal procedure. Page 4660 Parking Brake Cable: Service and Repair Parking Brake Cable-Rear Parking Brake Cable-Rear Removal and Installation Drum brake vehicles 1. Remove the rear drum brake shoes. Disc brake vehicles 2. With the vehicle in NEUTRAL, position it on a hoist. All vehicles 3. Release the parking brake control boot clips at the floor console by pressing inward on the base of the boot. 4. Remove the parking brake control boot. ^ Pull the parking brake control boot up and over the lever. 5. Loosen the front cable adjuster nut. 6. Disconnect the cable connector from the LH rear parking brake cable at the equalizer. 7. If removing the LH rear parking brake cable, remove the 2 parking brake equalizer bracket bolts. ^ To install, tighten to 9 Nm (80 inch lbs.). 8. If removing the LH rear parking brake cable, remove the cable-to-fuel tank strap clip. 9. If removing the LH rear parking brake cable, disconnect the front parking brake cable from the equalizer bracket by compressing the cable conduit locking tabs. 10. Remove the cable bracket-to-body bolt. ^ To install, tighten to 23 Nm (17 ft. lbs.). 11. Remove the cable bracket-to-trailing arm bolt. ^ To install, tighten to 23 Nm (17 ft. lbs.). Drum brake vehicles Page 2336 Oil Pressure Sender: Service and Repair Oil Pressure Sender Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 5 bolts and the RH splash shield. ^ To install, tighten to 9 Nm (80 inch lbs.). 3. Disconnect the oil pressure sender electrical connector. 4. Remove the oil pressure sender. ^ To install, tighten to 15 Nm (11 ft. lbs.). 5. To install, reverse the removal procedure. ^ Apply pipe sealant with Teflon to the oil pressure sender threads. Page 4903 Relay Box: Diagrams Smart Junction Box (SJB) Page 4566 Brake Pad: Service and Repair Rear Brake Pads Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 2 brake caliper guide bolts. ^ To install, tighten to 35 Nm (26 ft. lbs.). 3. CAUTION: Do not allow the brake caliper to hang by the brake caliper jounce hose. Remove the brake caliper and secure the brake caliper to the vehicle. 4. Remove the inboard and outboard brake pads from the brake caliper. 5. To install, reverse the removal procedure. Page 7656 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 5416 Wheel Bearing: Service and Repair Rear Wheel Bearing Testing and Inspection Mini ISO Relay: Testing and Inspection Page 6475 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 1727 2. NOTE: Do not remove the rear knuckle cam nut and wheel knuckle bolts. If removed, clean the serrations in the bushing sleeve with a wire brush and install a new wheel knuckle bolt and cam nut. Loosen the LH and RH rear wheel knuckle bolts. 3. Turn the LH and RH adjusting cams simultaneously until the toe is within specification. 4. Tighten the LH and RH rear wheel knuckle bolts. ^ Using a suitable tool, hold the adjustment cam nut stationary while tightening the rear wheel knuckle bolt. ^ Tighten to 115 Nm (85 ft. lbs.). Locations Page 7540 Symbols Part 5 Page 4066 Pressure Plate: Testing and Inspection Clutch Pressure Plate Check 1. Check the clutch pressure plate surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth. 2. Measure the flatness of the clutch pressure plate surface with a straightedge and a feeler gauge. 3. Check the diaphragm spring fingers for discoloration, scoring and bent or broken segments. 4. Measure the wear of the diaphragm spring fingers. Page 2707 Oxygen Sensor: Description and Operation HEATED OXYGEN SENSOR (HO2S) Heated Oxygen Sensor (HO2S) The HO2S detects the presence of oxygen in the exhaust and produces a variable voltage according to the amount of oxygen detected. A high concentration of oxygen (lean air/fuel ratio) in the exhaust produces a voltage signal less than 0.4 volt. A low concentration of oxygen (rich air/fuel ratio) produces a voltage signal greater than 0.6 volt. The HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a voltage between 0.0 and 1.1 volts. Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to a temperature of 800°C (1400°F). At approximately 300 °C (600°F) the engine can enter closed loop operation. The VPWR circuit supplies voltage to the heater. The PCM will turn on the heater by providing the ground when the proper conditions occur. The heater allows the engine to enter closed loop operation sooner. The use of this heater requires the HO2S heater control to be duty cycled, to prevent damage to the heater. Page 5977 19. Install the steering wheel access cover. 20. 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. Make sure all restraint system diagnostic tool(s) that may have been installed during the repair have been removed from the vehicle and all SRS components are connected. 21. Turn the ignition switch from OFF to ON. 22. Install RCM fuse F33 (15A) to the SJB and install the cover. 23. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in front of any air bag module when the battery ground cable is connected. Connect the battery ground cable. 24. Prove out the supplemental restraint system (SRS) as follows: Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will light continuously for approximately 6 seconds and then turn off. If an air bag supplemental restraint system (SRS) fault is present, the air bag indicator will: fail to light. - remain lit continuously. - flash. The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the OFF to the ON position. This is the time required for the restraints control module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault exists, a chime will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator and any SRS fault discovered must be diagnosed and repaired. Clear all continuous DTCs from the restraints control module using a diagnostic tool. Page 1719 Nibble Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and experienced by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Poor returnability and sticky steering are used to describe the poor return of the steering wheel to center after a turn or steering correction. Drift/Pull Pull is a tugging sensation felt by the hands on the steering wheel that must be overcome to keep the vehicle going straight. Drift describes what a vehicle with this condition does with the hands off the steering wheel. ^ A vehicle-related drift/pull on a flat road causes a consistent deviation from the straight-ahead path and requires constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (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). Effort may be said to be flat on-center. ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of the gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a driveability problem, it is important to understand the difference between wander and poor groove feel. Engine Controls - Long Crank/Hard Start PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Long Crank/Hard Start TSB 05-26-1 12/31/05 LONG CRANK/HARD START - 3.0L FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner ISSUE Some 2005-2006 Escape and Mariner 3.0L vehicles built from 7/19/2004 through 12/5/2005 may exhibit a long crank/hard start under either cold or hot engine conditions. ACTION Reprogram the powertrain control module (PCM) using WDS release B40.4 and higher or B41 .1 and higher. This new calibration is not included in the B41 CD. Calibration files may also be obtained at the website. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 052601A 2005-2006 Escape/Mariner 0.4 Hr. 3.0L Engine: Check For Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do not use with 12650D, 12650D84) DEALER CODING CONDITION BASIC PART NO. CODE RECALEM 04 Disclaimer Page 4235 Flex Plate: Diagrams Lower End Components-Exploded View Crankshaft Pulley and Crankshaft Front Oil Seal Page 5938 P0116 P0115 - P0119: Testing and Inspection P0116 P0116 (Part 1) P0116 (Part 2) Page 1264 Page 3666 Ignition Coil: Diagrams Page 7078 P0620 P0620 Page 3036 Main Relay (Computer/Fuel System): Testing and Inspection System Diagnosis P1729 Page 5652 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Page 5287 MERCURY: 2005-2011 Mariner This article supersedes TSB 10-1-9 to update the Service Procedure and model years. ISSUE Some 2001-2011 Escape and 2005-2011 Mariner vehicles may exhibit an underbody creak or squeak when accelerating from a stop or when braking to a stop. Depending on model year, the noise may appear to come from the front or rear underbody or suspension area. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 2001-2007 Only - Front - Creak/Squeak Noise: 1. Attach chassis ears to the areas indicated. Can the noise be isolated to one or both of these specific locations? (Figure 1) a. No - Do not continue with this procedure. Proceed to Workshop Manual (WSM), Section 100-04. b. Yes - Suspect the subframe locating pins are contacting the locating holes of the vehicle body. (1) Loosen the two (2) front subframe nuts and the two (2) front subframe attachment bolts. NOTE DO NOT ALLOW THE FRONT SUBFRAME REAR BOLTS TO COME OUT OF THE LOWER CONTROL ARM BUSHING. (2) Reposition the subframe to center the locating pins so there is no longer contact with any edge of the locating hole. (Figure 2) NOTE THE PINS ARE MORE LIKELY TO CONTACT THE REARWARD SIDE OF THE HOLES. THEREFORE, THE SUBFRAME ASSEMBLY WILL MOST LIKELY NEED TO BE MOVED FORWARD IN VEHICLE. Page 2258 Engine Oil Pressure: Capacity Specifications Oil capacity .......................................................................................................................................... ........................................ 4.1 qts. + 0.4 qt. with filter Page 6532 Escape Is Shown, Mariner Is Similar (Part 2) Removal and Installation 1. Remove the front bumper cover. 2. Remove the 4 front bumper nuts. 3. Remove the front bumper. - To install, tighten to 25 Nm (18 lb-ft). 4. To install, reverse the removal procedure. Page 4085 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. Service and Repair Clutch Slave Cylinder: Service and Repair Clutch Slave Cylinder 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, wash it immediately with water. 1. Remove the transaxle. 2. Disconnect the clutch slave cylinder-to-clutch hydraulic fluid tube adapter. 3. Remove the 3 clutch slave cylinder bolts and the clutch slave cylinder. ^ To install, tighten to 12 Nm (9 ft. lbs.). 4. To install, reverse the removal procedure. ^ Bleed the air from the system. Page 3190 Page 2012 Relay Box: Locations Battery Junction Box Page 5402 the strut is installed. Remove the bearing plate. 9. Remove the bearing. 10. Remove the strut upper bushing. 11. Remove the dust boot and the bumper. 12. To assemble, reverse the disassembly procedure. Page 896 Blower Motor Relay: Testing and Inspection Page 302 P0457 Page 359 P0603 Page 7205 Symbols Part 5 Page 188 P0274 Page 116 P0172 Tires - Vibration Highway at Speeds Wheels: Customer Interest Tires - Vibration Highway at Speeds TSB 05-20-6 10/17/05 HIGHWAY SPEED VIBRATION - VEHICLES BUILT BEFORE 7/1/2005 EQUIPPED WITH CONTITRAC P235/70R16 104T TIRES FORD: 2005-2006 Escape MERCURY: 2005-2006 Mariner This article supersedes TSB 05-9-13 to update the Service Procedure. ISSUE Some 2005-2006 Escapes/Mariners built before 7/1/2005 equipped with Continental Contitrac(TM) P235/70R16 104T tires only, may exhibit a vibration at highway speeds over a wide speed range. ACTION Refer to the following Service Procedure to check the vehicle tires to determine if any need replacement. Only replace the individual tires identified as requiring replacement by the Service Procedure. SERVICE PROCEDURE NOTE THIS MESSAGE IS INTENDED TO ADDRESS FIRST ORDER TIRE VIBRATIONS. NOTE THE 20 MILE (32 KM) VIBRATION EVALUATION MUST BE PERFORMED TO REMOVE FLAT SPOTS. IF NOT, THE TIRE BALANCE AND ROAD FORCE MEASUREMENTS WILL NOT BE ACCURATE. 1. Drive the vehicle at highway speeds for 20 miles (32 km) to evaluate the vibration and eliminate flat spotting. NOTE IF THE VIBRATION GOES AWAY DURING THE 20 MILE (32 KM) VIBRATION EVALUATION, THE CONCERN IS DUE TO TIRE FLAT SPOTTING, WHICH IS A NORMAL TIRE CONDITION. NO FURTHER DIAGNOSIS OR REPAIRS SHOULD BE PERFORMED. 2. If road force measurement equipment (Hunter G5P9700/9712, or equivalent) is available, proceed to Step 3. If not, balance the tires with a standard balancer and use a dial indicator to locate and mark the high point of each tire's centerline radial runout. Record the runout measurement of each tire and wheel assembly. If this measurement exceeds .040" (1.02 mm) check to see if the wheel is bent or damaged. If the excess runout is attributable to the tire, replace with the appropriate (BSW or OWL) Continental P235/70R16 tire. The Continental Part Number for BSW is 9002 1548250-0000, the OWL Part Number is 9002 1548100-0000. Proceed to Steps 5 and 6. NOTE DO NOT USE THE SPARE TIRE AS A REPLACEMENT. NOTE THE PROCEDURE IN THIS TSB IS FAR MORE EFFECTIVE WHEN USING ROAD FORCE MEASUREMENT EQUIPMENT. ONLY USE A STANDARD BALANCER AND MANUALLY CHECK RUN OUT WHEN ABSOLUTELY NECESSARY. THERE IS A WEBSITE AVAILABLE TO LOCATE THE NEAREST FACILITY WITH ROAD FORCE EQUIPMENT AVAILABLE. NOTE SUPPRESS ROUND OFF FUNCTION ON ROAD FORCE BALANCER TO ALLOW ACTUAL RESIDUALS TO BE DISPLAYED. 3. Perform the road force measurement immediately after driving the vehicle. Remove the wheel assemblies. Measure the road force variation of all four (4) tires. Measure and mark the tire HIGH road force variation point (R1H) on all four (4) tires prior to dismounting them from the road force measurement equipment. Balance as required to 0.35 oz (log) or less of imbalance (check both two-plane and static). If any wheel assembly measures more than 18 lbs (8 kg) for R1H then proceed to Step 4. If less proceed to Step 5. 4. Using the road force measurement equipment, determine the low spot of the wheel run out. Match high point force variation on the tire with the Locations View 151-14 (Under Dash Panel, LH Side) Page 3008 F2-F7 Page 6763 Rear Subframe: Description and Operation REAR SUBFRAME The rear subframe is bolted to the body and is used to: - aid in structural support. - provide mounting surfaces for the rear suspension control arms. - provide mounting surfaces for the rear differential (4WD). Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension parts, and drivetrain operation. Window glass cracks, door and window opening concerns, and air or water leaks at the doors are often caused by improperly tightened bolts and body misalignment. Page 7429 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 1280 Backup Lamp Switch: Service and Repair REVERSING LAMP SWITCH Removal and Installation 1. Disconnect the reversing lamp switch electrical connector. 2. Remove the reversing lamp switch. - To install, tighten to 24 Nm (18 lb-ft). 3. To install, reverse the removal procedure. Description and Operation Side Air Bag: Description and Operation Driver Seat Side Air Bag Module NOTE: References to seat side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the SRS. - For additional information, when servicing a seat equipped with a seat side air bag module, refer to Seats. A seat side air bag module provides protection of the thorax area (between the neck and abdomen) of the body, working in conjunction with the head protection provided by a safety canopy module. Only Escape Hybrid, Mariner and late build Escape vehicles equipped with safety canopy modules are equipped with seat side air bag modules. The driver seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the driver seat side impact sensor and internal RCM circuitry. - is installed as an assembly. - is mounted in the driver seat back. - is used in conjunction with a safety canopy module on Escape Hybrid, Mariner and late build Escape vehicles only (seat side air bag modules are not equipped on early build Escape vehicles). Passenger Seat Side Air Bag Module NOTE: References to seat side air bag modules refer to the seat-mounted and not to the steering wheel or instrument panel mounted air bag components of the SRS. - For additional information, when servicing seat equipped with a seat side air bag module, refer to Seats. A seat side air bag module provides protection of the thorax area (between the neck and abdomen) of the body, working in conjunction with the head protection provided by a safety canopy module. Only Escape Hybrid, Mariner and late build Escape vehicles equipped with safety canopy modules are equipped with seat side air bag modules. The passenger seat side air bag module: will deploy upon receiving a flow of current from the RCM initiated by the passenger seat side impact sensor and internal RCM circuitry. - is installed as an assembly. - is mounted in the passenger seat back. - is used in conjunction with a safety canopy module on Escape Hybrid, Mariner and late build Escape vehicles only (seat side air bag modules are not equipped on early build Escape vehicles). Page 1941 Refrigerant: Service and Repair Evacuation and Charging AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING Special Tool(s) Special Tool(s) Refrigerant System Evacuation Using an R-134a Refrigerant Center NOTE: - Use of a refrigerant center is recommended to carry out recovery, evacuation, and charging of the refrigerant system. If a refrigerant 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 equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle refrigerant system. It is necessary to leak-test all refrigerant system equipment, hoses and gauges on a weekly basis to verify that no leaks are present. Turbine Shaft Speed (TSS) Sensor Transmission Speed Sensor: Service and Repair Turbine Shaft Speed (TSS) Sensor Turbine Shaft Speed (TSS) Sensor Material Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Remove the 7 retainers and the LH splash shield. ^ To install, tighten to 10 Nm (89 inch lbs.). 3. Remove the turbine shaft speed (TSS) sensor. 1. Disconnect the TSS electrical connector. 2. Remove the TSS sensor bolt. 3. Remove the TSS sensor. ^ To install, tighten to 13 Nm (10 ft. lbs.). 4. NOTE: When installing the sensor, lubricate the O-ring seal with clean transmission fluid. Page 71 P0128 Page 5305 Be Claimed With B, C And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208B 2001-20007 Escape, 0.2 Hr. 2005-2007 Mariner, 2005-2007 Escape Hybrid, 2006-2007 Mariner Hybrid: Includes Time To Adjust Front Sub Frame Following Service Procedure. Can Be Claimed With Operation A, C, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208C 2001-2011 Escape, 0.2 Hr. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Adjust Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 5523 Removal and Installation 1. Remove the instrument panel center finish panel. 2. Release the tabs and remove the RH and LH center registers. 3. To install, reverse the removal procedure. PASSENGER SIDE REGISTER Body - Door Seal Squeaking Weatherstrip: All Technical Service Bulletins Body - Door Seal Squeaking TSB 05-22-11 11/14/05 DOOR SEAL SQUEAKS FORD: 2001-2005 Escape 2005 Escape Hybrid MERCURY: 2005 Mariner ISSUE Some 2001-2005 Escape, 2005 Escape Hybrid and Mariners may exhibit squeaks from the shedlip seal for the doors. This seal runs along the top edge of the doors, above the top section of the individual door inner seals. This is most likely to be noticed at slow speeds and when the body is put into a twist. ACTION Replace the seals. Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 052211A 2001-2005 Escape, 2005 0.2 Hr. Escape Hybrid, 2005 Mariner: Replace The Shedlip Seal For Both Doors DEALER CODING CONDITION BASIC PART NO. CODE 7851222 41 OASIS CODES: 110000, 702000 Disclaimer Page 3821 Fluid - A/T: Fluid Type Specifications Ford Part Name - MERCON(R) V Automatic Transmission Fluid Ford Part Number - XT-5-QM Ford Specification - MERCON(R) V Page 7157 Removal NOTE: 2.3L is shown, 3.0L is similar. 1. Remove the accelerator cable snow shield. 2. Disconnect the speed control cable from the throttle lever and accelerator cable bracket. 3. Press the locking tab and rotate the speed control cable cap to remove. Page 1811 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Page 6445 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 Locations View 151-8 (Engine, rear) Page 6375 View 151-18 (Full Body, Right Rear - 2 Of 2) Page 5563 Removal 1. Remove the A/C compressor. 2. Using the special tool, remove the A/C clutch bolt. 3. Remove the A/C disc and hub assembly and the A/C clutch hub spacers. 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 clutch disc and hub assembly and the A/C clutch disc and hub spacers from the compressor shaft. Diagrams Page 1760 4. Inspect for normal burning. ^ Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. ^ Install a new spark plug. 6. Inspect for overheating, identified by a white or light gray spots and with bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. ^ Install a new spark plug. 7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. ^ Install new spark plugs. Page 7026 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. Locations View 151-10 (Automatic Transmission) Page 2990 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 4179 Page 364 P0606 Page 7619 Symbols Part 3 Page 5948 Air Bag Control Module: Service and Repair RESTRAINTS CONTROL MODULE (RCM) 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 restraints control module (RCM) orientation is critical for correct air bag supplemental restraint system (SRS) operation. If a vehicle equipped with an SRS system has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM is restored to its original condition. - 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. - To reduce the risk of personal injury, do not use any memory saver devices. 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 air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault. - 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. Depower the system. Page 5318 Rear Sub Frame Following Service Procedure. Must Be Claimed With Operation A, B, And D (Do Not Use With Any Labor Operations Outside Of This Article) 102208D 2001-2011 Escape, 1.1 Hrs. 2005-2011 Mariner, 2005-2011 Escape Hybrid, 2006-2011 Mariner Hybrid: Includes Time To Check And Adjust Camber, Caster, And Toe Can Be Claimed With A, B, And C (Do Not Use With Any Labor Operations Outside Of This Article) DEALER CODING CONDITION BASIC PART NO. CODE 5035 07 Disclaimer Page 1173 View 151-15 (Full Body, Left Rear - 1 Of 2) Page 1682 2. Disconnect the electrical connectors. 3. Remove the 2 multifunction switch screws. 4. Remove the multifunction switch. 5. To install, reverse the removal procedure. Bleeding, Components Brake Bleeding: Service and Repair Bleeding, Components Brake System Bleeding Special Tool(s) Material Anti-Lock Brakes Bleed WARNING: Use of any other than the approved DOT 3 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: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. 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. NOTE: Bleeding the hydraulic control unit (HCU) is required only when removing or installing the HCU, master cylinder, or opening the lines to the HCU. 1. NOTE: Carrying out the System Bleed function drives trapped air from the HCU. Subsequent bleeding removes the air from the brake hydraulic system through the bleeder screws. NOTE: Adequate voltage to the HCU module is required during the anti-lock control portion of the system bleed. Connect the diagnostic tool. 2. Access the SYSTEM BLEED FUNCTION. Go to the Tool Tab-Chassis-Braking-ABS Service Bleed and follow the directions on the diagnostic tool. 3. Manually bleed the brake hydraulic system. 4. Repeat the procedure carrying out a total of 2 diagnostic tool cycles and 2 manual bleed cycles. Page 3010 F10-F11 Normal Operation The parking aid module and the restraint control module (RCM) communicate with the diagnostic tool through the ISO 9141 communication network circuit 70 (LB/WH). If circuit 70 (LB/WH) becomes open or shorted to ground, communication to those modules is not possible. Check circuit 70 (LB/WH) between the parking aid module C4014, RCM C2041a and the data link connector (DLC) C251. Total resistance values must not be more than 5 ohms. If the resistance is more than 5 ohms, there is an open in circuit 70 (LB/WH), damage to the DLC C251, damage to the parking aid module, the RCM, or a problem in one of the in-line connectors. If, after individual checks of each circuit leading to a module show resistance values less than 5 ohms and no in-line connector issues present, the data link diagnostics test must be run with the module in question disconnected. If the data link diagnostics test passes with the module in question disconnected, the module is the source of the concern. A new module should be installed. Possible Causes NOTE: Although the ABS module does not use the ISO 9141 communication network for communication, it is connected to ISO 9141 communication network circuit 70 (LB/WH), and should be tested to eliminate the module as a potential source of network problems. - ISO 9141 communication network circuit 70 (LB/WH) shorted to ground or open - DLC C251 - parking aid module (if equipped) - RCM - ABS module Test G: No Medium Speed Controller Area Network (CAN) Communication PINPOINT TEST G: NO MEDIUM SPEED CONTROLLER AREA NETWORK (CAN) COMMUNICATION G1 Page 5157 Removal and Installation CAUTION: While 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. NOTE: New O-rings must be installed any time the lines are disconnected from the steering gear. 1. Drain the power steering fluid into a suitable drain pan. 2. Release the clamp and disconnect the steering gear-to-fluid cooler return hose from the power steering cooler. 3. Remove the steering gear-to-fluid cooler return hose bracket-to-steering gear stud. ^ To install, tighten to 10 Nm (89 inch lbs.). 4. Remove the steering gear-to-fluid cooler return hose bracket-to-subframe bolt. ^ To install, tighten to 10 Nm (89 inch lbs.). 5. Remove the power steering line clamp plate bolt. ^ To install, tighten to 25 Nm (18 inch lbs.). 6. NOTE: The power steering pressure and return lines are of different diameters and the O-rings are not interchangeable. Rotate the clamp plate and remove the steering gear-to-fluid cooler return hose. ^ Install a new return hose O-ring seal. 7. To install, reverse the removal procedure. ^ Fill the power steering system. Heated Oxygen Sensor (HO2S) Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) HEATED OXYGEN SENSOR (HO2S) Exploded View Socket, Exhaust Gas Oxygen Sensor Special Tool(s) Removal and Installation 1. With the vehicle in NEUTRAL, position it on a hoist. 2. Disconnect the battery ground cable. 3. Disconnect the heated oxygen sensor (HO2S) electrical connector. Description and Operation Fuel Pressure Test Port: Description and Operation PRESSURE TEST POINT On some applications there is a pressure test point with a Schrader fitting in the fuel rail that relieves the fuel pressure and measures the fuel injector supply pressure for repair and diagnostic procedures. Before repairing or testing the fuel system, read any WARNING, CAUTION, and HANDLING information. On vehicles not equipped with a Schrader valve, use the Rotunda Fuel Pressure Test Kit #134-R0087 or equivalent. Locations Specifications Timing Cover: Specifications Engine front cover bolts Tighten the bolts in the sequence shown, to the following specifications: Tighten the 8-mm bolts to ......................................................................................................................................................... 10 Nm (89 inch lbs.). Tighten the 13-mm bolts to ........................................................................................................................................................... 48 Nm (35 ft. lbs.). A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Page 760 P2015 - P2019: Testing and Inspection P2019 P2019 (Part 1) P2019 (Part 2)

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